System and apparatus for robotic device and methods of using thereof

ABSTRACT

A robotic assembly control system is disclosed. The robotic assembly control system includes an exoskeleton apparatus adapted to be worn by a user, at least one robotic assembly, the at least one robotic assembly controlled by the user by way of the exoskeleton, and at least one mobile platform, the at least one mobile platform controlled by the user and wherein the at least one robotic assembly is attached to the at least one mobile platform.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 13/083,245, filed Apr. 8, 2011 and entitled System andApparatus for Robotic Device and Method of Using Thereof, now U.S. Pat.No. 9,844,447, issued Dec. 19, 2017, which is a Non-Provisionalapplication which claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/322,469, filed Apr. 9, 2010 and entitledExoskeleton System and Apparatus for Robotic Device and Methods of UsingThereof, each of which is hereby incorporated herein by reference in itsentirety.

TECHNICAL FIELD

The present development relates to mechanical devices and, moreparticularly, to robotic devices. More particularly, the developmentrelates to a system and apparatus for robotic device and methods ofusing thereof.

BACKGROUND INFORMATION

For many reasons, there may be a desire for a task to be completedwithout the direct intervention of a human. For example, but not as alimiting example, there exist methods and tasks that are dangerous,hazardous and/or harmful for a human to perform. Some of these tasks mayinclude those with high risk of bodily injury or death. These include,but are not limited to, the handling of or contact with hazardousmaterials and working with explosives. Additionally, some environmentsmay be inherently dangerous for humans. However, for many reasons, itmay be necessary and/or desirable for a human to handle dangerousmaterials and/or be in an environment that may be inherently dangerous.

Accordingly, there is a need for a system for performing tasks that maybe harmful to a human, under the control of a human, either in the sameenvironment as the task is performed or remotely. Thus, there is a needfor a system and apparatus to control a robotic device such that thehuman is not required to be in the same environment as the roboticdevice and/or the human is not required to perform the task.

SUMMARY

In accordance with one aspect of the present invention, a roboticassembly control system is disclosed. The robotic assembly controlsystem includes an exoskeleton apparatus adapted to be worn by a user,at least one robotic assembly, the at least one robotic assemblycontrolled by the user by way of the exoskeleton, and at least onemobile platform, the at least one mobile platform controlled by the userand wherein the at least one robotic assembly is attached to the atleast one mobile platform.

In accordance with one aspect to the present invention, a method formapping movement by a user to a remote robotic assembly is disclosed.The method includes collecting signals from a plurality of sensorsreflecting movement of the user, and

mapping the signals to control the movement of at least one roboticassembly,

wherein the mapping ratio of the user movement to the remote roboticassembly may change at preprogrammed points in the path of the usermovement.

In accordance with one aspect to the present invention, a method formapping movement by a user to a robotic assembly is disclosed. Themethod includes collecting signals from sensors reflecting movement ofthe user, and mapping the signals to control the movement of at leastone robotic assembly.

Some embodiments of this aspect of the present invention may include oneor more of the following. Wherein the method further includesdetermining the center point of rotation of a shoulder, measuring theshoulder abduction with at least one potentiometer, measuring theshoulder flexion with at least one potentiometer, and mapping themovement of a shoulder and translating the movement of the shoulder tomovement of a robotic device.

In accordance with one aspect to the present invention, a roboticassembly control system is disclosed. The system includes an exoskeletonapparatus adapted to be worn by a user, at least one robotic assembly,the at least one robotic assembly controlled by the user by way of theexoskeleton, and

at least one mobile platform, the at least one mobile platformcontrolled by the user and wherein the at least one robotic assembly isattached to the at least one mobile platform.

Some embodiments of this aspect of the present invention may include oneor more of the following. Wherein the exoskeleton further includes anattachment system comprising a plurality of straps, the attachmentsystem for attaching to a user, and a frame including a lower portionand an upper portion wherein the upper portion telescopingly connects tothe lower portion wherein the frame is adjustable. Wherein the framefurther comprising a ball detent mechanism for adjusting the frame.Wherein the system further including at least one potentiometer. Whereinthe system further including at least two ball joints. Wherein thesystem further including a compliance section wherein the compliancesection senses sternoclavicular motion by a user. Wherein the compliancesection is a torsion spring. Wherein the torsion spring is preloadedwith a hard stop, wherein the hard stop is adjustable. Wherein thesystem further including at least one tactor motor wherein the at leastone tactor motor provides feedback from at least one joint on the atleast one robotic assembly. Wherein the system further including atactor strap for each tactor motor wherein the tactor strap attaches toa user. Wherein the at least one tactor motor is a vibration motor.Wherein the exoskeleton further including a hand portion comprising atleast one force sensor. Wherein the hand portion comprising a thumbforce sensor, an index finger sensor and a middle finger sensor. Whereinthe thumb force sensor further comprising at least one potentiometer.Wherein the hand portion further comprising at least one tactor motorwherein the tactor motor provides feedback of the robotic assembly thumbgrip to the user.

These aspects of the invention are not meant to be exclusive and otherfeatures, aspects, and advantages of the present invention will bereadily apparent to those of ordinary skill in the art when read inconjunction with the appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bebetter understood by reading the following detailed description, takentogether with the drawings wherein:

FIG. 1 is a perspective view of one embodiment of a prosthetic armapparatus according to the present invention;

FIG. 2 is an exploded view of the prosthetic arm apparatus of FIG. 1;

FIG. 3 is a rear view of a shoulder abductor of the prosthetic armapparatus of FIG. 1 according to the present invention;

FIG. 4 is a front view of the shoulder abductor of FIG. 3;

FIG. 5 is a side view of the shoulder abductor of FIG. 3;

FIG. 6 is a perspective view of the shoulder abductor of FIG. 3;

FIG. 7 is an exploded perspective view of the shoulder abductor of FIG.6;

FIG. 8 is a perspective view of a shoulder flexion assembly of theprosthetic arm apparatus of FIG. 1 according to the present invention;

FIG. 9 is a reverse perspective view of the shoulder flexion assembly ofFIG. 8;

FIG. 10 is an exploded perspective view of the shoulder flexion assemblyof FIG. 8;

FIG. 11 is a cross-sectional perspective view of the shoulder flexionassembly of FIG. 8;

FIG. 12 is a top view of a non-backdriving clutch according to thepresent invention;

FIG. 13 is a perspective view of a fully assembled compliancesubassembly of the shoulder flexion assembly of FIG. 8;

FIG. 14 is a perspective view of the bottom portion of the compliancesubassembly of FIG. 13;

FIG. 15 is a perspective view of the top portion of the compliancesubassembly of FIG. 13;

FIG. 16 is a perspective view of a humeral rotator of the prosthetic armapparatus of FIG. 1 according to the present invention;

FIG. 17 is a cross-sectional perspective view of the humeral rotator ofFIG. 16;

FIG. 18 is a perspective view of an elbow flexion assembly of theprosthetic arm apparatus of FIG. 1 according to the present invention;

FIG. 19 is a cross-sectional perspective view of one embodiment of theelbow flexion 15 assembly shown without the radial mount;

FIG. 20 is a cross-sectional perspective view of the elbow flexionassembly shown with the radial mount;

FIG. 21 is a perspective view showing the compliance subassembly of theelbow flexion assembly of FIG. 19;

FIG. 22 is an exploded perspective view of the elbow flexion assembly ofFIG. 18;

FIG. 23 is a perspective view of a wrist rotator of the prosthetic armapparatus of FIG. 1 according to the present invention;

FIG. 24 is a cross-sectional perspective view of the wrist rotator ofFIG. 23;

FIG. 25 is a perspective view of a wrist flexion assembly and a handcontrol module of the prosthetic arm apparatus of FIG. 1 according tothe present invention;

FIG. 26 is a rear perspective view of the wrist flexion assembly andhand control module of FIG. 25;

FIG. 27 is a cross-sectional perspective view of the wrist flexionassembly and hand control module of FIG. 25;

FIG. 28 is a perspective view of a wrist assembly output arm of FIG. 25;

FIG. 29 is a side view of a hand assembly of the prosthetic armapparatus of FIG. 1 according to one embodiment;

FIG. 30 is a front view of one embodiment of the hand assembly of FIG.29;

FIG. 31 is a perspective view of one embodiment of the hand assembly ofFIG. 29 showing an index finger tensioner assembly;

FIG. 32 is a cross-sectional view of one embodiment of the hand assemblyof FIG. 29 showing an MRP tensioner assembly;

FIG. 33 is a front cross-sectional view of one embodiment of the MRPdifferential drive of FIG. 30;

FIG. 34 is a front cross-sectional view of one embodiment of thumbdifferential drives of FIG. 30;

FIG. 35 is a side view of one embodiment of the hand assembly of FIG. 30showing a tactile feedback sensor according to the present invention;

FIG. 36 is a perspective view of one embodiment of the tactile feedbacksensor and a feedback actuator of the prosthetic arm apparatus of FIG.1;

FIG. 37 is a perspective view of another embodiment of the tactilefeedback sensor and feedback actuator of the prosthetic arm apparatus ofFIG. 1 according to the present invention;

FIG. 38 is an exploded view of a portion of the hand showing anotherembodiment of the index and MRP fingers drives;

FIG. 39 is an exploded view of another embodiment of the hand;

FIG. 40 is a perspective view of another embodiment of the hand;

FIG. 41 is a perspective cutaway view of the hand;

FIG. 42 shows an embodiment of an integrated shoulder unit according toan embodiment of the present invention;

FIG. 43 is a partial cutaway view of the integrated shoulder unit ofFIG. 42 in an inactuated state;

FIG. 44 is a partial cutaway view of the integrated shoulder unit ofFIG. 42 in an actuated state;

FIG. 45 is a cross sectional view of another embodiment of an integratedshoulder unit according to the present invention;

FIG. 46 is a cross sectional view of another embodiment of theintegrated shoulder unit of FIG. 45;

FIG. 47 is a top view of a shoulder abductor and shoulder flexionassembly according to another embodiment of the present invention;

FIG. 48 is a side plane view of shoulder flexion assembly mount of theshoulder abductor of FIG. 47;

FIG. 49 is a cross-sectional view of one embodiment of a rotatoraccording to the present invention;

FIG. 50 is a side view of one embodiment of a flexion assembly accordingto the present invention;

FIG. 51 is a front view of the flexion assembly of FIG. 50;

FIG. 52 is a perspective view of another embodiment of a wrist flexionassembly according to the present invention;

FIG. 53 is a partially exploded perspective view of the wrist flexionassembly of FIG. 52;

FIG. 54 is a top cross-sectional view of the wrist flexion assembly ofFIG. 52;

FIG. 55 is a top cross-sectional view of the wrist flexion assembly ofFIG. 52;

FIG. 56 is a cross-sectional view of another embodiment of a wristflexion assembly according to the present invention;

FIG. 57 is a partial cross sectional view of another embodiment of thenon-backdriving clutch of FIG. 12;

FIG. 58 is a perspective view of a compliance assembly according to anembodiment of the present invention;

FIG. 59 is a side view of a breakaway mechanism according to anembodiment of the present invention;

FIG. 60 is a front cross-sectional view of the breakaway mechanism ofFIG. 59;

FIG. 61A-63B are various views of another embodiment of a breakawaymechanism according to the present invention;

FIG. 64 is a front view of a magnetic sensor according to someembodiments of the present invention;

FIG. 65 is a side cross-sectional view of another embodiment of amagnetic sensor according to the present invention;

FIG. 66 is a cross-sectional view of a hand assembly according to anembodiment of the present invention;

FIG. 67 is a front view of a hand assembly cosmesis according to anembodiment of the present invention;

FIG. 68A is a front view of an embodiment of the cosmesis of FIG. 67with removable finger portions;

FIG. 68B is a cross-sectional view of an embodiment of a fingerstructure cosmesis of FIG. 68A;

FIG. 69 is a perspective view of another embodiment of the cosmesis ofFIG. 67;

FIG. 70 is a perspective view of a prosthetic arm apparatus having atemperature sensor according to an embodiment of the present invention;

FIG. 71 is a side view of a thumb structure according to an embodimentof the present invention;

FIG. 72 is a side cross-sectional view of the thumb structure of FIG.71;

FIG. 73 is a side cross-sectional view of the thumb structure of FIG. 71under a load;

FIG. 74 is a top view of a humeral rotator and an elbow flexion assemblyaccording to another embodiment of the present invention;

FIG. 75A is a perspective view of a prosthetic arm apparatus having anemergency switch according to an embodiment of the present invention;

FIG. 75B is a perspective view of a prosthetic arm apparatus having anemergency switch according to an embodiment of the present invention;

FIG. 76 is a perspective view of a wrist flexion assembly according toanother embodiment of the present invention;

FIG. 77 is a perspective view of a first cam bearing of the wristflexion assembly of FIG. 76;

FIG. 78 is a perspective view of a second cam bearing of the wristflexion assembly of FIG. 76;

FIG. 79A is a perspective view of the wrist flexion assembly of FIG. 76in a first position;

FIG. 79B is a perspective view of the wrist flexion assembly of FIG. 76in a second position;

FIG. 79C is a perspective view of the wrist flexion assembly of FIG. 76in a third position;

FIG. 80 is a line graph of a fixed movement path of the wrist flexionassembly of FIG. 76;

FIG. 81 is a view of one embodiment of the exoskeleton worn by a user;

FIG. 82 is a view of one embodiment of the mobile platform;

FIG. 83 is an illustrative cross sectional view of one embodiment of theattachment point to the mobile platform;

FIG. 84A is an isometric view of one embodiments of the exoskeleton;

FIG. 84B is a front view of one embodiments of the exoskeleton;

FIG. 84C is a side view of one embodiments of the exoskeleton;

FIG. 84D is a back view of one embodiments of the exoskeleton;

FIG. 85A is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 85B is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 86A is a view of one embodiment of a hand of the exoskeletondetached from an exoskeleton;

FIG. 86B is a view of one embodiment of a hand of the exoskeletondetached from an exoskeleton;

FIG. 86C is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 86D is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 86E is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 86F is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 86G is a view of one embodiment of an arm of the exoskeletondetached from an exoskeleton;

FIG. 87 is an illustrative view of one embodiment of the system;

FIG. 88 is an illustrative view of one embodiment of the system;

FIG. 89 is an illustrative view of one embodiment of the system;

FIG. 90 is an illustrative view of one embodiment of the system;

FIG. 91 is an illustration of one embodiment of a communication systemand method; and

FIGS. 92A-92C are illustrations of various embodiments of the system;

FIG. 93 is a flow chart of one embodiments of a control method.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In some embodiments, the system includes at least one roboticassembly/apparatus and at least one exoskeleton and/or system forcontrol of the at least one robotic assembly. The robotic assembly mayinclude, but is not limited to, a prosthetic and/or robotic arm and/orhand, which, in some embodiments, may be one of the various embodimentsof prosthetic/robotic hands/arms described below. However in someembodiments, the system may include at least one robotic apparatus,which, in some embodiments, may be a prosthetic arm, but in otherembodiments, may be any robotic apparatus including, but not limited to,a robotic hand, a robotic arm, a robotic leg, a robotic foot and/or arobotic being that may resemble a robotic human or a robotic mammal. Insome embodiments, the robotic assembly/apparatus may be anyassembly/apparatus with at least one robotic feature.

In some embodiments, the system includes at least two robotic arms,complete with hands. In some embodiments, the at least one robotic armmay be attached to a device which may be a mobile platform. However, insome embodiments, the device may not be attached to a mobile platform,but rather, may be attached to anything, including, but not limited to,a wall, floor or other non-movable structure. In some embodiments, thedevice may be attached to a structure which may be movable, however, maynot be “mobile” in the sense that it may not include one or more wheels.In some embodiments, at least one, and in some embodiments, at leasttwo, prosthetic arms may be attached to a structure, and in someexemplary embodiments, at least two prosthetic arms may be attached to amobile platform.

In some embodiments, the robotic assembly may not require attachment toany structure but rather, may be a stand alone robotic object.

The system may include at least one exoskeleton apparatus. Theexoskeleton apparatus may be adapted to be worn/configured to be worn bya being of any size. In some embodiments, the exoskeleton may beadjustable such that the exoskeleton may be configured to any user. A“user” may be defined as anything, whether human, other mammalian orrobotic, that may wear the exoskeleton. In the exemplary embodiments,the exoskeleton is used to at least partially/partly control the atleast one robotic assembly. In some embodiments, the exoskeleton may beused to fully control the at least one robotic assembly.

In some embodiments, the exoskeleton may be worn by a human and used tocontrol two robotic arm/hand assemblies. In some embodiments, theexoskeleton may also include at least one component for control of amobile platform to which the two robotic arm/hand assemblies are mountedby way of at least one compliant feature. In some embodiments, theexoskeleton may control the at least one robotic assembly from a remotelocation, including, but not limited to, using wireless communication.

In some embodiments, the robotic assembly may be controlled using acamera mapping/camera tracking device which may, using a camera, trackthe movements of a user, and map the movement of the user onto therobotic assembly. In some embodiments, the cameral mapping/cameratracking device may be one known in the art, for example, the OspreyDigital RealTime System made by Motion Analysis Corporation, Santa Rosa,Calif., U.S.A, however, other system may also be used.

As discussed above, in the exemplary embodiment, the robotic assembly isa robotic arm/hand assembly which may be referred to herein, forpurposes of description, as a prosthetic arm apparatus. In someembodiments, the prosthetic arm apparatus may be one described below.Referring to FIGS. 1 and 2, a prosthetic arm apparatus 10 for attachmentto a shoulder of a shoulder disarticulated amputee includes a pluralityof segments, including a shoulder abductor 12, a shoulder flexionassembly 14, a humeral rotator 16, an elbow flexion assembly 18, a wristrotator 20, a wrist flexion assembly 22, and a hand assembly 24. Theprosthetic arm apparatus 10, in the exemplary embodiment, has thedimensions and weight of a female arm of a fiftieth percentile, so thatmany different users may comfortably use the prosthetic arm apparatus10. As should be understood by those skilled in the art, the prostheticarm apparatus 10 may be constructed to larger or smaller dimensions ifdesired. The prosthetic arm apparatus 10 may be controlled by a controlsystem (not shown), such as the various control systems described inU.S. patent application Ser. No. 12/027,116, filed Feb. 6, 2008, nowU.S. Publication No. US-2008-0243265, published Oct. 2, 2008 andentitled METHOD AND APPARATUS FOR CONTROL OF A PROSTHETIC DEVICE; U.S.patent application Ser. No. 12/706,609, filed Feb. 16, 2010, now U.S.Publication No. US-2010-0274365, published Oct. 28, 2010 and entitledARM PROSTHETIC DEVICE; U.S. patent application Ser. No. 12/706,471,filed Feb. 16, 2010, now U.S. Publication No. US 2010-0211185, publishedAug. 19, 2010 and entitled SYSTEM, METHOD AND APPARATUS FOR ORIENTATIONCONTROL each of which is hereby incorporated by reference in itsentirety.

Referring to FIG. 3, one embodiment of the shoulder abductor 12 isshown. The shoulder abductor 12 includes a harness mount 26 forconnecting the prosthetic arm apparatus 10, shown in FIG. 1, to asupport apparatus, as the various prosthetic supports described in U.S.patent application Ser. No. 12/026,971, filed Feb. 6, 2008, now U.S.Publication No. US-2009-0271000, published Oct. 29, 2009 and entitledDYNAMIC SUPPORT APPARATUS; U.S. patent application Ser. No. 12/706,340,filed Feb. 16, 2010, now U.S. Publication No. US-2010-0211189, publishedAug. 19, 2010 and entitled DYNAMIC SUPPORT APPARATUS AND SYSTEM, each ofwhich is hereby incorporated by reference in its entirety. The harnessmount 26 has harness interface holes 28 that may be used to attach theabductor 12 to a prosthetic harness (not shown) or other system forsupporting the prosthetic arm apparatus 10. In the exemplary embodiment,the harness or prosthetic support apparatus may also be one disclosed inco-pending U.S. patent application Ser. No. 12/026,971, filed Feb. 6,2008, now U.S. Publication No. US-2009-0271000, published Oct. 29, 2009and entitled DYNAMIC SUPPORT APPARATUS, which is hereby incorporated byreference in its entirety.

Referring to FIG. 4, the shoulder abductor 12 also has a shoulderflexion assembly mount 30, shown according to one embodiment. Theshoulder flexion assembly mount 30 interfaces with the shoulder flexionassembly 14 to mount the shoulder flexion assembly 14 onto the shoulderabductor 12. In one embodiment, the flexion assembly mount 30 hasinterface holes 32 to facilitate connection of the shoulder flexionassembly 14 by attachment means such as bolts.

Referring to FIG. 5, the shoulder abductor 12 further includes anabductor joint 34, shown according to one embodiment. The abductor joint34 is used to pivot the shoulder flexion assembly mount 30 away from theharness mount 26 and back toward the harness mount 26.

Referring to FIGS. 6 and 7, the shoulder abductor 12 includes anabductor motor 36 to control the pivotal movement of the abductor joint34, both the shoulder abductor 12 and abductor motor 36 shown accordingto one embodiment. In this embodiment, the abductor motor 36 is abrushed DC motor controlling the pivotal movement through an abductorbelt 38 connected to a worm drive 41 driving a worm wheel 39 connectedto an abductor harmonic drive gearing system 40.

Referring to FIGS. 8 and 9, the shoulder flexion assembly 14, in oneembodiment, has a main shoulder housing 42, with an abductor interface44 for connecting the shoulder flexion assembly 14 to the shoulderabductor 12. The shoulder flexion assembly 14 also has a humeralinterface 46 for connecting the humeral rotator 16 to the shoulderflexion assembly 14.

Referring to FIGS. 10 and 11, in one embodiment, shoulder flexion motormagnets 52 are disposed around a shaft 58 of a shoulder flexion motorrotor 54. In this embodiment, a shoulder flexion motor armature 55drives the shoulder flexion motor rotor 54, which in turn drives ashoulder flexion motor pulley 56 around a motor shaft 58. The shoulderflexion motor pulley 56 supports a shoulder flexion belt 60, which islinked between the shoulder flexion motor pulley 56 and a shoulderflexion belt-driven pulley 62. The shoulder flexion belt-driven pulley62 drives a shoulder flexion harmonic drive gearing system wavegenerator 64. A shoulder flexion harmonic drive gearing systemflexspline 66 rotates against the shoulder flexion harmonic drivegearing system wave generator 64 and a shoulder flexion harmonic drivegearing system circular spline 68, resulting in reduced speed for thejoint movement. The shoulder flexion harmonic drive gearing systemflexspline 66 is connected to the abductor interface 44, and is thusable to rotate the shoulder flexion assembly 14 in reference to theabductor interface.

Referring to FIG. 11, in one embodiment, a non-backdriving clutch 70 isdisposed inside the main shoulder housing 42. The non-backdriving clutch70 allows the prosthetic arm 10 to hold position by locking when theprosthetic arm 10 is not moving.

Referring to FIG. 12, in one embodiment, roller bearings 72 line theinterface between an input cage 74 and an output hex 76. When a force isapplied to the shoulder abductor interface 44, the output hex 76 locksagainst the bearing race 78 and the roller bearings 72. This preventsthe shoulder flexion assembly 14 from moving due to force applied to itsoutput, shoulder abductor interface 44. Upon the exertion of a necessaryamount of input force through the clutch input cage 74, the output hex76 disengages and allows the shoulder flexion assembly 14 to move. Theclutch input cage 74 and the output hex 76 are both constrained by aclutch race 78. It should be understood by those skilled in the art,that other mechanisms could be used to prevent backdriving of theprosthetic arm 10, such as a clutch that locks in one direction or asolenoid with brakes that engage when the solenoid is powered.Additionally, although described in connection with the shoulder flexionassembly 14, it should be understood by those skilled in the art thatthe non-backdriving clutch 70 may be included in other prosthetic jointsdescribed herein.

Referring to FIG. 13, in one embodiment, a compliance subassembly 50includes a compliance reactor 80 positioned on top of the shoulderflexion harmonic drive gearing system circular spline 68 and held inplace by the clamp 82. The compliance reactor 80 measures the amount ofdisplacement in the compliance subassembly 50 in relation to theposition of a compliance sensor magnet 84.

Referring to FIG. 14, in one embodiment, the interior of compliancesubassembly 50 includes series elastic elements 86. The shoulder flexionharmonic drive gearing system circular spline 68 defines the interior ofthe compliance subassembly 50 and is formed to accommodate the placementof the series elastic elements 86 around an outer diameter 87 of theshoulder flexion harmonic drive gearing system circular spline 68. Theseries elastic elements 86 are confined by the shoulder flexion harmonicdrive gearing system circular spline 68 and the clamp 82.

Referring to FIG. 15, the placement of the compliance reactor 80 inrelation to the series elastic elements 86 and reactor elements 88 isshown. In this embodiment, three reactor elements 88 are positionedaround the compliance reactor 80, equidistant to each other. One serieselastic element 86 is placed on either side of each reactor element 88.When the shoulder flexion assembly 14 is subjected to unexpected force,such as a sudden jolt or impact, the compliance reactor 80 and reactorelements 88 displace from their rest positions and compress against theseries elastic elements 86. In that way, the compliance subassembly 50attenuates the shock being transferred to the rest of the shoulderflexion assembly 14. The compliance reactor 80 may also measure theamount of displacement and compliance by measuring the movement of thecompliance reactor 80 in relation to the stationary position of thecompliance sensor magnet 84.

Referring to FIG. 16, one embodiment of the humeral rotator 16 is shown.The humeral rotator 16 includes an outer bearing carrier 90 attached tothe first control housing 92, shown in FIG. 2. The first control housing92, shown in FIG. 2, is used to connect the humeral rotator 16 to theshoulder flexion assembly 14. The inner rotational elements of thehumeral rotator are held in place by a clamp 94, which is fastened tothe outer bearing carrier 90. A humeral mount 96 passes through theclamp 94 and includes an elbow interface 98 for attaching the elbowflexion assembly 18 to the humeral rotator 16.

FIG. 17 shows a cross-sectional view of the humeral rotator 16. Ahumeral motor armature 100 drives a humeral motor rotor 102 havinghumeral magnets 104 disposed on its surface. The lower portion of themotor rotor 102 engages a humeral harmonic drive gearing system wavegenerator 106. A humeral harmonic drive gearing system flexspline 108rotates with the humeral harmonic drive gearing system wave generator106 against the humeral harmonic drive gearing system circular spline110, resulting in a speed of rotation reduction as the humeral harmonicdrive gearing system flexspline 108 causes the humeral mount 96 to move.Bearings 111 and 113 support the humeral motor rotor 102. Bearings 112support the harmonic drive gearing system components 106, 108, 110. Abearing support 114 caps the outer bearing carrier 90 between the outerbearing carrier 90 and the first control housing 92.

Still referring to FIG. 17, the one embodiment, a humeral potentiometer116 of the humeral rotator 16, measures the rotational displacement of ahumeral potentiometer shaft 118 that rotates proportionately to thehumeral mount 96.

Referring to FIG. 18, the elbow flexion assembly 18 includes an elbowjoint 120 and a radial mount 122. The elbow joint 120 includes a slot124 into which the elbow interface 98 of the humeral rotator is insertedto facilitate connection of the elbow flexion assembly 18 to the humeralrotator 16. The radial mount 122 provides a second electronics housing126, in which an ACM stack 128 is located. “ACM” as used herein refersto Arm Control Module. The radial mount 122 includes a wrist interface130, for attachment of the wrist rotator 20.

Referring to FIG. 19, the elbow joint 120 includes an elbow motorarmature 132 that drives an elbow motor rotor 134. Elbow magnets 136 aredisposed at one end of the motor rotor 134, and the opposing end of themotor rotor 134 has a sun gear 138. As the motor armature 132 drives thesun gear 138, the sun gear 138 in turn drives four planetary gears 140positioned equidistant from each other around the sun gear 138. The fourplanetary gears 140 in turn react against a ring gear 142, giving theelbow flexion assembly 18 a first stage of speed reduction through anelbow harmonic drive gearing system wave generator 148 which also actsas the planet carrier. The elbow harmonic drive gearing system wavegenerator 148 powers the elbow harmonic drive gearing system flexspline146, which drives against the elbow harmonic drive gearing systemcircular spline 144, giving the elbow flexion assembly 18 a second stageof reduction. The elbow harmonic drive gearing system flexspline 146then drives the motion of the elbow flexion assembly 18. Bearings 150and crossed roller bearings 152 support the outer perimeter of the elbowflexion assembly 18. Although described with both a planetary gearsystem and an elbow harmonic drive gearing system, the elbow flexionassembly 18 could be controlled solely by a harmonic drive gearingsystem by changing the gear reduction ratio.

In various embodiments, it may be desirable to avoid having to performadditional measurement by using the measurement in the complianceprocess. One example includes, in various embodiments, where theplanetary gears may be used for compliance and measurement of load.

Referring to FIG. 20, in the embodiment shown, the radial mount 122 isstructurally fixed to the elbow joint 120, such that when the elbowjoint is actuated, the radial mount 122 moves.

Referring to FIG. 21, an elbow compliance subassembly 154 isincorporated into the elbow flexion assembly 18. A plurality of arms 156extends from the center portion of the elbow compliance subassembly 154.Each arm 156 has an elbow series elastic element 158 disposed on eitherside of the arm 156. Similar to the shoulder flexion assembly 14, if theelbow flexion assembly 18 is subject to a torque, the elbow compliancesubassembly 154, with its series elastic elements 158, is capable ofabsorbing the shock attenuating the torque magnitude through the rest ofthe elbow flexion assembly 18.

Referring to FIG. 22, the ACM stack 128, includes circuit boards 160connected to one another by structural standoffs 162. The structuralstandoffs 162 are constructed of a conductive material, so thatelectrical power may be passed through the circuit boards 160. Thestructural standoffs allow power to be supplied to each circuit board160 without conventional power connections.

Referring to FIG. 23, the wrist rotator 20 includes a wrist outerbearing carrier 164, a wrist clamp 166, a wrist potentiometer 168, anelbow interface 170, and a wrist flexion assembly interface 172.

Referring to FIG. 24, movement of the wrist rotator 20 is controlled bya harmonic drive gearing system similar to that described for thehumeral rotator. A wrist rotator motor armature 174 drives a wristrotator motor rotor 176 having wrist rotator magnets 178 disposed to itssurface. The lower portion of the wrist rotator motor rotor 176integrates a wrist rotator harmonic drive gearing system wave generator180. A wrist rotator harmonic drive gearing system flexspline 182rotates with the wrist rotator harmonic drive gearing system wavegenerator 180 against a wrist rotator harmonic drive gearing systemcircular spline 184, resulting in reduction in the speed of rotation asthe wrist rotator harmonic drive gearing system flexspline 182 causesthe wrist flexion assembly interface 172 to move with respect to therest of the wrist rotator 20. Bearings 185 support the wrist rotatormotor rotor 176. Bearings 186 support the harmonic drive gearing systemcomponents 180, 182, and 184.

Still referring to FIG. 24, the wrist potentiometer 168 of the wristrotator 20 is disposed at one end of a wrist shaft 188 and measures therotational displacement thereof. The wrist shaft 188 may be tubular,having an electronics channel 190 for passing electronic power andcontrols through the wrist rotator 20.

Referring to FIG. 25, the wrist flexion assembly 22 includes handcontrol module circuit boards 192, an input support structure 194, anoutput arm 196, and a hand interface 198. The input support structure194 connects the wrist rotator 20 with the wrist flexion assembly 22.The output arm 196 has positive and negative flexion, such that theoutput arm 196 is able to move in two opposite directions in referenceto the support structure 194. The hand interface 198 allows the handassembly 24 to be connected to the wrist flexion assembly 22. Referringto FIG. 26, the wrist flexion assembly 22, has wrist electricalconnections 200 for supplying power to a wrist flexion motor 202.

Referring to FIG. 27, in the embodiment shown, the wrist flexion motor202 drives a wrist flexion output gear 204, which in turn drives a wristflexion final stage-driven gear 206. A wrist flexion pivot axle 208 ofthe output arm 196 is axially disposed inside an opening defined by theinterior of the wrist flexion final stage-driven gear 206. Wrist flexionseries elastic elements 210 are disposed in the interior of the outputarm 196. Movement of the wrist flexion final stage-driven gear 206facilitates the positive and negative motion of the output arm 196. Anon-backdriving clutch 212 is disposed at one end of the wrist flexionoutput gear 204.

Referring to FIG. 28, the output arm 196 has a wrist flexion drive arm214, which is driven by the wrist flexion final stage-driven gear 206.The end of the wrist flexion drive arm 214 accommodates a wrist flexioncompliance sensor magnet 216. The wrist flexion series elastic elements210 are disposed on either side of the wrist flexion drive arm 214, andthe wrist flexion series elastic elements 210 and the drive arm 214 aresubstantially enclosed within the output arm 196. Similar to the elbowflexion assembly 18 and the shoulder flexion assembly 14, if the wristflexion assembly 22 is subjected to a force, the wrist flexion drive arm214 compresses the wrist flexion series elastic elements 210 andattenuates the force or impact through the rest of the wrist flexionassembly 22.

The following is a description of one embodiment of the hand assembly.Other embodiments of the hand assembly are described and shown elsewherein this specification. Referring to FIGS. 29 and 30 the hand assembly 24includes a hand support 218 for providing an interface for connectingthe hand assembly 24 to the wrist flexion output arm 196. The handassembly 24 also includes a thumb structure 220, an index fingerstructure 222, and an MRP structure 224 replicating a middle finger 226,a ring finger 228, and a pinky finger 230. In various embodiments, thethumb structure 220 may be driven by two thumb drives 232 that feed intoa single differential, giving the thumb structure 220 two degrees offreedom of movement. The index finger structure 222 may be driven by asingle index drive 234 and the MRP structure 224 may be driven by asingle MRP drive 236 that feeds a double differential. The MRP approachallows for an indeterminate versus determinate linkage.

Referring to FIG. 31, the index finger structure 222 (not shown) isdriven by the index drive 234 through an index drive pulley 238, anindex tensioner 240, an index tension belt 242, and an index fingerpulley 244. The index drive pulley 238 is stage driven and transfers thetorque to the index tension belt 242, which in turn rotates the indexfinger pulley 244, causing the index finger structure 222 to move. Asthe index tension belt 242 transfers the torque, one side of the indextension belt 242 tightens and the other side loosens, depending on whichdirection the index drive pulley 238 is rotated. The index tensioner 240is located between the index drive pulley 238 and the index fingerpulley 244 and the index tensioner 240 displaces in relation to thechange in load to maintain the tension of the index tension belt 242.The index tensioner 240 has one side grounded and the other side capableof displacement upon the application of a load. The index tensioner 240may instead ground the moveable side of the index tensioner 240 with aspring.

Referring to FIG. 38, in another embodiment, the index finger structure222 is driven through an index sun shaft 350, a set of index planets352, an index planet carrier 354, an index ring gear 356, and an indexdrive gear 358. The index drive 360 drives the index ring gear 356,turning the index planets 352, the turning of which causes the indexplanet carrier 354 to rotate. The index drive gear 358 is driven by theexternal teeth of the index planet carrier 354, causing the indexstructure 222 to move. Any torque transmitted by the index planetcarrier 354 will react against the index sun shaft 350 causing it torotationally displace the index spring 362 through the index springmount 364. This rotational displacement, sensed by an indexpotentiometer 366 can be used to infer the load on the index fingerstructure 222. This rotational displacement may be used to store elasticenergy and to provide the index finger structure 222 with a measure ofcompliance that may aid in gripping and with load absorption.

Referring to FIG. 31, the thumb structure 220 is mounted on a thumbsupport 246, which is driven by the two thumb differential drives 232.The thumb structure 220 has flexural cuts 248 at its base allowing thecompliant thumb structure 220 to move when a load is applied to it. Thiscompliance in the thumb structure 220 may aid in gripping and with loadabsorption, which may prevent the hand assembly 24 from damaging objects(not shown) by closing around them too quickly and forcefully.

Referring to FIG. 32, the hand assembly 24 includes an MRP drive pulley250 driven by the MRP drive 236 (not shown). The MRP drive pulley 250 isconnected through an MRP tension belt 252 to the MRP pulley 254,enabling movement of the MRP structure 224. The MRP drive pulley 250 isstage driven and transfers the load to the MRP tension belt 252, whichin turn rotates the linked MRP structure 224 via the MRP pulley 254. Asthe MRP tension belt 252 transfers torque, one side of the MRP tensionbelt 252 tightens as the other side loosens. An MRP tensioner 256located at one side of the MRP tension belt 252 displaces in relation tothe change in load to maintain the tension of the MRP tension belt 252.This also provides the MRP structure 224 with compliance to aid ingripping and with load absorption, which may prevent the hand assembly24 from damaging objects (not shown) by closing around the objects (notshown) too quickly and forcefully.

Referring to FIG. 38, in another embodiment, the MRP finger structures224 are driven through an MRP sun shaft 370, a set of MRP planets 372,an MRP planet carrier 374, an MRP ring gear 376, and an MRP drive gear378. The MRP drive 380 drives the MRP ring gear 376, turning the MRPplanets 372, the turning of which causes the MRP planet carrier 374 torotate. The MRP drive gear 378 is driven by the external teeth of theMRP planet carrier 374, causing the MRP structures 224 to move. Anytorque transmitted by the MRP planet carrier 374 will react against theMRP sun shaft 370 causing it to rotationally displace the MRP spring 382through the MRP spring mount 384. This rotational displacement can beused to store elastic energy.

Referring to FIG. 33 the MRP differential drive 236 includes a main MRPdrive gear 258. The MRP drive gear 258 drives a first MRP input axle260. The first MRP input axle 260 drives a first differential idler gear259 which optionally drives a middle spur gear 262 or a differentialinterface gear 261. The middle spur gear 262 drives a middle pivot axle264. The middle finger 226 is mounted on the middle pivot axle 264 andis thus actuated by the MRP differential drive 236. The differentialinterface gear 261 drives a second MRP input axle 266. The second MRPinput axle 266 drives a second differential idler gear 263 whichoptionally drives a ring spur gear 268 or a pinky spur gear 272. Thering spur gear 268 drives a ring pivot axle 270. The ring finger 228 ismounted on the ring pivot axle 270 and is thus actuated by the MRPdifferential drive 236. The pinky spur gear 272 drives a pinky pivotaxle 274. The pinky finger 230 is mounted on the pinky pivot axle 274and is thus actuated by the MRP drive 236. While the MRP drive 236drives the middle finger 226, the ring finger 228 and the pinky finger230, the gear configuration of the first input axle 260 and the secondinput axle 266 allows independent movement for the under-actuated fingergear system of the MRP structures 224.

Referring to FIG. 41, in another embodiment of the hand, the MRPdifferential drive includes an MRP drive gear 378 which drives a doubledifferential allowing the MRP fingers to conformably wrap around anobject. The MRP drive gear 378 drives a first MRP input axle 400. Thefirst input axle 400 drives a first differential idler gear 402 whichoptionally drives a middle spur gear 404 or a differential interfacegear 406. The middle spur gear 404 drives a middle pivot axle 264. Themiddle finger 226 is mounted on the middle pivot axle 264 and is thusactuated by the MRP drive 236. The differential interface gear 406drives a second MRP input axle 408. The second MRP input axle 408 drivesa second differential idler gear 410 which optionally drives a ring spurgear 412 or a pinky spur gear 414. The ring spur gear 412 drives a ringpivot axle 270. The ring finger 228 is mounted on the ring pivot axle270 and is thus actuated by the MRP drive 236. The pinky spur gear 414drives a pinky pivot axle 274. The pinky finger 230 is mounted on thepinky pivot axle 274 and is thus actuated by the MRP drive 236. Whilethe MRP drive 236 drives the middle finger 226, the ring finger 228 andthe pinky finger 230, the gear configuration of the first input axle 400and the second input axle 408 allows independent movement for theunder-actuated finger gear system of the MRP structures 224.

Referring to FIG. 34 the thumb differential drives 232 control themovement of the thumb structure 220 and are driven by thumb actuators276. The thumb actuators 276 have nonbackdriving thumb clutches 278 toprevent output loads from reaching and backdriving the thumb actuators.One thumb actuator 276 drives a first thumb output drive 280 and a firstthumb output gear 282. The first thumb output gear 282 in turn drives afirst thumb transfer gear 284, which drives a fixed differential shaft286. The fixed differential shaft 286 drives one thumb differentialbevel gear 287. The second thumb actuator 276 drives a second thumboutput drive 288 and a second thumb output gear 290. The second thumboutput gear 290 drives a second thumb transfer gear 292, which drives athumb differential bevel gear 294. The two thumb differential bevelgears 287 and 294 operate the thumb structure 220 in its two degrees ofmotion.

The thumb structure 220, the index finger structure 222, and MRPstructure 224 in one embodiment are covered in silicone, which providesadditional friction and aids in gripping objects. In some embodiments,the entire hand assembly 24 may also be covered in silicone to provideadditional grip for holding objects. In other embodiments, the siliconematerial may be replaced by other compliant materials.

The hand assembly 24 is advantageous because the thumb structure 220,index finger structure 222 and MRP structure 224 provide various degreesof freedom that allow the formation of various grasps or grips.Additionally, the different drives for each of the thumb structure 220,index finger structure 222 and MRP structure 224 provide variousbeneficial characteristics to the hand assembly 24. For instance, thethumb structure 220 moves relatively slow, but with greater force thanthe index finger structure 222 and MRP structure 224. The index fingerstructure 222 moves quickly, but with less force and isnon-backdrivable. This combination of thumb structure movement and indexfinger structure movement allow the quick formation of strong handgrips. Additionally, the combination allows for a smaller index fingeractuator, which reduces size and weight of the hand assembly 24.Additionally, the index finger structure 222 and MRP structure 224 movesimilar to human fingers, which makes them look more natural and makesthem more intuitive for the user to control. The MRP structure 224provides only bulk control for gripping objects, without providing forindividual finger manipulation, since fine control is not necessary forthe MRP structure 224. Additionally, the MRP structure 224advantageously moves each finger of the MRP structure 224 with a singleactuator, eliminating excessive bulk in the hand assembly 24. Like theindex finger structure, the MRP structure 224 moves quickly with lowforce but is also non-backdrivable. Additionally, the fingers of the MRPstructure 224 are highly flexible, allowing them to grip objects ofvarying size and shape. The MRP structure 224 functionality allows theuser to grasp an object with the MRP structure 224 and thumb structure220, while allowing the user to move the index finger structure 222separately, for example, to activate a button on the object.

The various parts of the prosthetic arm apparatus 10 are, in someembodiments, constructed from plastic or magnesium. However, where morestrength is desired, the parts may be made of aluminum, titanium orsteel. In other embodiments, the various parts of the prosthetic arm maybe constructed of other metals or plastics, depending on the desiredcharacteristics, including strength, weight, compliance or other similarperformance characteristics of the various parts.

Referring to FIG. 35, a tactile feedback sensor 296 may be positioned onthe inner side of the thumb structure 220. The tactile feedback sensor296 may be a pressure sensor, force sensor, a displacement sensor, orother similar sensor capable of providing the user with feedback.Referring to FIG. 36, the tactile feedback sensor 296 is operativelyconnected to a feedback actuator 298. The tactile feedback sensor 296may be connected to the feedback actuator 298 by either wires orwirelessly. In operation, as the user grips an object with the handassembly 24, feedback sensor 296 reads the displacement of or the forceexerted on the thumb structure 220. That reading is then sent to thefeedback actuator 298, which gives the user tactile feedback thatindicates the strength of the grip. Feedback actuator 298 may be placedon the chest of the user, located on a prosthetic support apparatus 299in an area of tactile communication with the user, or in any otherlocation capable of receiving tactile feedback, such as on a user'sresiduum 300. Referring to FIG. 37, the feedback actuator 298 may belocated on a foot controller 302 that is used to control hand assembly24.

Feedback actuator 298 may be a vibration motor, such as any vibrationmotor known in the art, placed against the skin of the user. As the usergrips an object, feedback actuator 298 begins vibrating, notifying theuser how strong the object is being gripped. As the force on ordisplacement of the tactile feedback sensor 296 changes, frequencyand/or amplitude of vibration may also change, notifying the amputee ofa changing grip. For example, if a vibrating actuator 298 is placed atthe chest of the user as in FIG. 36, the user will feel the vibration athis chest.

The feedback actuator 298 may also be placed wherever the controller forthe hand assembly 24 is located. For example, if a foot controller 302controls the hand assembly 24, the feedback actuator 298 may beincorporated into the foot controller 302. The user will then receivetactile feedback of the strength of the prosthetic grip at the samelocation where the controller is located.

The actuator 298 may also be a pressure actuator that applies pressureagainst the user's skin. For example, the actuator 298 may have a rodthat increases pressure against the amputee's skin as the hand assembly24 increases its grip on an object.

Although described with a single tactile feedback sensor 296, additionaltactile feedback sensors may be placed at other locations on the handassembly 24. For example, additional tactile feedback sensors 296 may beplaced on the index finger structure 222, the MRP structures 224, on thepalm of the hand assembly 24, or on any combination of these positionsor any other location. Each tactile feedback sensor 296 would then beoperatively connected to an associated feedback actuator 298. Multipletactile feedback sensors 296 and actuators 298 would provide moresophisticated tactile feedback of the strength of the grip, improvingthe control of the hand assembly 24.

In some embodiments, the tactile feedback sensor 296 may indicate achange in pressure or force, rather than an absolute pressure or force.For example, if the force detected by the tactile feedback sensor 296 isconstant, the feedback actuator 298 does not actuate, but if thatpressure or force increases or decreases, the actuator 298 would actuateto indicate the change in pressure or force. Additionally, althoughdescribed in terms of grip strength, the tactile feedback sensors 296and actuators 298 may provide a variety of other feedback in includingtemperature, an operational mode of the prosthetic arm 10, surfacefinish of a object, slip of an object within the hand assembly 24 or thelike.

In operation, the prosthetic arm apparatus is able to move substantiallysimilar to a human arm. Referring to FIGS. 29 and 30, starting with thehand assembly 24, the thumb structure 220, index finger structure 222,and MRP structure 224 are each driven independent of the others, andtherefore, each may be actuated without actuating the other twostructures. Both of the thumb actuators 276 control motion of the thumbstructure 220 in a direction toward or away from the center of the palmof the hand assembly 24, as shown in FIG. 34, through the miter gear 294and in a direction toward or away from the side of the palm of the handassembly 24, as shown in FIG. 34, through the lateral rotation shaft,depending upon the direction and speed of rotation of each thumbactuator 276. Thus, the thumb actuators 276, shown in FIG. 34, providethe thumb structure 220 with two degrees of freedom in the thumbstructure's movement. Coupling the two thumb actuators 276 through thedifferential described above to provide the two degrees of freedom tothe thumb structure 220 is advantageous over providing a single degreeof freedom with each actuator 276 because the torque of each actuator276 through the differential is used for movement in both degrees offreedom, which effectively doubles the torque of the thumb in eachdirection as compared to single actuators. The index finger structure222, driven by a single index differential drive 234, may be actuatedwith two degrees of freedom. Specifically, the index finger structure222 may be actuated toward or away from the palm of the hand assembly24, wherein the movement path is similar to that of a human index fingerwhile making or releasing a fist. The middle finger 226, ring finger228, and pinky finger 230 of the MRP structure 224 are actuated by theMRP differential drive 236. Additionally, the middle finger 226, ringfinger 228, and pinky finger 230 are actuated toward or away from thepalm of the hand assembly 24, similar to the index finger structure 222.However, the middle finger 226, ring finger 228, and pinky finger 230are each geared separately, such that the rate of movement of each isdifferent, simulating human finger movement and making the hand assembly24 more similar to a human hand than conventional prior art prostheticdevices.

Referring to FIG. 1, the hand assembly 24 is mounted on the wristflexion assembly 22 via the hand interface 198, as shown in FIG. 25.Referring to FIG. 25, as the output arm 196 of the wrist flexionassembly 22 is actuated, the hand assembly 24 is also caused to move.The output arm 196 of the wrist flexion assembly 22 may be actuatedpivotally about wrist flexion pivot axle 208, as shown in FIG. 27,moving the hand interface 198 to the left or right, and thus pivotingthe hand assembly 24 in relation to the input support structure 192.

Referring back to FIG. 1, the wrist flexion assembly 22 is attached tothe wrist rotator 20 via wrist flexion assembly interface 172, shown inFIG. 23. Referring to FIGS. 23 and 24, when actuated, the wrist flexionassembly interface 172 is rotated about wrist shaft 188 in relation to10 the wrist outer bearing carrier 164. Therefore, the wrist flexionassembly 22, and attached hand assembly 24 are also caused to rotate inreference to the wrist outer bearing carrier 164 by actuation of thewrist rotator 20. Therefore, the wrist rotator 20 allows the prostheticarm apparatus 10 to move in rotation similar to a human wrist joint.

Referring back to FIG. 1, the wrist rotator 20 is attached to the elbowflexion assembly 18 via the wrist interface 130, shown in FIG. 18.Referring to FIG. 20, when the elbow flexion assembly 18 is actuated,the radial mount 122 is rotated about the axis of motor rotor 134. Thewrist rotator 20, wrist flexion assembly 22, and hand assembly 24 arethus also caused to rotate about the axis of motor rotor 134 becausethey are attached at the wrist interface to the radial mount 122.Therefore, the elbow flexion joint 18 allows the prosthetic armapparatus 10 to move similar to flexion extension of a human elbowjoint.

Referring back to FIG. 1, the elbow flexion assembly 18 is attached tothe humeral rotator 16 via the humeral mount 96, shown in FIG. 27.Referring to FIG. 16, actuation of the humeral rotator 16 causes thehumeral mount 96 to rotate in relation to the outer bearing carrier 90of the humeral rotator 16. Since the elbow flexion assembly 18, wristrotator 20, wrist flexion 25 assembly 22, and hand assembly 24 areattached to the humeral mount 96, they are also caused to rotate inrelation to the outer bearing carrier 90. This allows the prosthetic armapparatus 10 to rotate to perform an arm wrestling motion.

Referring back to FIG. 1, the humeral rotator 16 is attached to theshoulder flexion assembly 14 through the humeral interface 46, shown inFIG. 9. Referring to FIG. 9, actuation of the shoulder flexion assembly14 causes the main shoulder housing 42 to pivot about the center of theabductor interface 44. Since the humeral rotator 16, elbow flexionassembly 18, wrist rotator 20, wrist flexion assembly 22, and handassembly 24 are attached to the main housing 42, they are also caused torotate in relation to the abductor interface 44. Therefore, the shoulderflexion assembly 14 allows the prosthetic arm apparatus 10 to move alongthe torso simulating running motion.

Referring to FIG. 1, the shoulder flexion joint 14 is attached to theshoulder abductor 12 through the shoulder flexion assembly mount 30,shown in FIG. 5. Referring to FIG. 5, the shoulder abductor 12 isattached to a harness that is worn by the user via harness mount 26.When the shoulder abductor 12 is actuated in a positive direction, theshoulder flexion assembly mount 30 pivots away from the harness mount26, and the user. Similarly, by actuating the shoulder abductor in anegative direction, the shoulder flexion assembly mount 30 is pivotedtoward the harness mount 26 and the user. Since the shoulder flexionassembly 14, humeral rotator 16, elbow flexion assembly 18, wristrotator 20, wrist flexion assembly 22, and hand assembly 24 are attachedto shoulder abductor 12 at the flexion assembly mount 30, they are alsocaused to pivot with the shoulder flexion assembly mount 30.

One characteristic of the prosthetic arm apparatus described herein isthat it provides the user with substantially the same movementcapabilities and degrees of freedom of a human arm, including twodegrees of freedom in shoulder functionality. Additionally, themodularity of each segment of the prosthetic arm apparatus 10 provides asignificant advantage over conventional prosthetic devices. Inparticular, since each segment of the plurality of segments operatesindependently of each other segment of the plurality of segments, fewersegments may be used for less severe amputees. For example, atranshumeral amputee may have full shoulder functionality in theresiduum, in which case the shoulder abductor 12 and shoulder flexionassembly 14 segments would be omitted from the prosthetic arm apparatus10. The resulting prosthetic arm apparatus 10 would include the humeralrotator 16, the elbow flexion assembly 18, the wrist rotator 20, thewrist flexion assembly 22, and the hand assembly 24, wherein the humeralrotator 16 would be attached to the prosthetic harness. In some cases,the residuum of the transhumeral amputee may even have humeral rotation,in which case the prosthetic arm apparatus 10 may be further simplifiedto include only the elbow flexion assembly 18, the wrist rotator 20, thewrist flexion assembly 22 and the hand assembly 24, with the elbowflexion assembly 22 being attached to the prosthetic support apparatus.Similarly, for a transradial amputee, the prosthetic arm apparatus 10may include only the wrist rotator 20, wrist flexion assembly 22 and thehand assembly 24, with the wrist rotator 20 being attached to theprosthetic support apparatus. Additionally, in some embodiments, theprosthetic arm apparatus 10 may be further simplified to include onlythe wrist flexion assembly 22 and the hand assembly 24 when thetransradial amputee has wrist rotation in their residuum. In theseembodiments, the wrist flexion assembly 22 may be attached to theprosthetic support apparatus. Thus, the modularity of each segment ofthe prosthetic arm apparatus 10 advantageously allows for customizationof different prosthetic arm configurations for various users based onthe differing degrees of amputation of each user.

A further advantage of the present invention is the use ofnon-backdriving clutches to preclude movement of the segments due toforces exerted on the prosthetic arm apparatus 10 when not in motion.These non-backdriving clutches may be particularly beneficial when thesegments of the prosthetic arm apparatus 10 have different strengthcapacities so that the clutches for specific segments of the prostheticarm apparatus 10 may lock those segments while other stronger segmentsare actuated to lift heavy objects. For instance, the non-backdrivingclutch in the shoulder flexion assembly 14 may be used to lock outshoulder movement while the elbow flexion assembly 18 is actuated tolift a heavy object. The non-backdriving clutches may alsoadvantageously conserve power since the non-backdriving clutches preventmotion without using power. Thus, the power to specific segments of theprosthetic arm apparatus 10 may be shut off, on a segment-by-segmentbasis, when not in use, since the non-backdriving clutches in thosesegments are locking out motion. Additionally, the non-backdrivingclutches may also save power by allowing power to the entire prostheticarm apparatus 10 to turned off whenever the arm is not in motion whilemaintaining the prosthetic arm apparatus 10 in a locked position.

An additional characteristic of the apparatus is that the hand assemblyincludes independently moving fingers and is capable of completing finetasks such as pinching, grasping non-uniform objects, and lifting smallobjects off flat surfaces. Also, the tactile feedback sensor providesthe user with feedback, during use of the prosthetic arm apparatus, suchas the force of a grip. The apparatus also includes a cosmesis coveringon the finger structures, which will be discussed in greater detailbelow, providing, amongst other things, grip for grasping objects. Therigid fingernail 304, which may be included on any of the fingerstructures, provides a backstop for the finger cover to enhance grippingcapability. The rigid fingernail 304 also enhances gripping capabilityby anchoring the finger cover to the finger and allows the user to liftsmall objects from a surface with the prosthetic arm apparatus 10.

Referring to FIG. 42, wherein like numerals represent like elements, insome embodiments, the shoulder abductor 12 and the shoulder flexionassembly 14 shown in FIG. 2, may be integrated as a single shoulder unit1416, providing both degrees of freedom provided by the shoulderabductor 12 and shoulder flexion assembly 14 of FIG. 2. The singleshoulder unit 1416 includes a shoulder housing 1418 pivotally connectedto the harness mount 1026, which allows the shoulder unit 1416 to beconnected to a prosthetic harness (not shown) as discussed above. Insome embodiments, the shoulder housing 1418 has a smooth outer surface1419 to shape the shoulder unit 1416 to be similar to a human arm. Theshoulder housing 1418 is divided into a flexor portion 1420 and anabductor portion 1422, which are movable relative to one another. Theflexor portion 1420 of the shoulder housing 1418 includes the humeralinterface 1046 for connecting the humeral rotator 16, shown in FIGS. 1and 2, to the shoulder unit 1416. The abductor portion 1422 of theshoulder housing 1418 is pivotally connected to the harness mount 1026,which allows the shoulder unit 1416 to interface with a prostheticharness (not shown) as discussed above.

Referring to FIGS. 43 and 44, within the housing 1418 is a shoulderflexion drive 1424 for causing flexion motion of the flexor portion 1420about a shoulder flexion axis 1426 and an abduction drive 1428 forcausing abduction motion of the shoulder housing 1418 about an abductionaxis 1430. Additionally, the housing also defines an electronicscompartment 1432 for housing control systems and circuits for theintegrated shoulder unit 1416.

The shoulder flexion drive 1424, in one embodiment, includes a shoulderflexion motor 1434 having motor shaft 1058 for driving the shoulderflexion motor pulley 1056. The shoulder flexion motor pulley 1056 drivesthe shoulder flexion belt 1060, which, in turn, drives the shoulderflexion belt-driven pulley 1062. The shoulder flexion belt-driven pulley1062 drives the wave generator 1064 of a shoulder flexion harmonic drivegearing system 1436, the output of which is fixedly interfaced with theabductor portion 1422. Thus, as power is transmitted through theshoulder flexion drive 1424 from the shoulder flexion motor 1434 to theoutput of the harmonic drive gearing system 1436, the flexor portion1420 rotates relative to the abductor portion 1422 about the shoulderflexion axis 1426. In some embodiments, the motor shaft 1058 and thewave generator 1064 are both hollow shafts to allow passage of anabductor motor shaft 1438 and an abductor screw shaft 1440,respectively, as will be discussed in greater detail below.

In the exemplary embodiment, the abduction drive 1428 includes theabductor motor 1036 for driving the abductor motor shaft 1438. Theabductor motor shaft 1438 is configured to drive the abductor belt 1038about its distal end. The abductor belt 1038, in turn, drives theabductor screw shaft 1440, which has an abductor nut 1442 threadedlycoupled thereto. The abductor nut 1442 is connected to the harness mount1026 through a linkage 1444, which is, in some embodiments, a four barlinkage. As power is transmitted through the abductor drive 1426 fromthe abductor motor 1036 to the abductor screw shaft 1440, the screwshaft 1440 rotates. The rotation of the screw shaft 1440 causes theabductor nut 1442 to displace axially along the screw shaft 1440, whichcauses pivotal motion of the shoulder housing 1418 through the linkage1444 about the abduction axis 1430.

The relative movement between the flexor portion 1420 and the abductorportion 1422 provides the shoulder unit 1416 with a first degree offreedom similar to that of the shoulder flexion joint 14 of FIG. 2. Theabductor portion 1422 of the shoulder housing 1418 is pivotallyconnected to the harness mount 1026 at the abductor joint 1034,providing the shoulder unit with the second degree of freedom byallowing the shoulder housing 1418 to pivot relative to the harnessmount 1026 in a similar manner to that discussed above in connectionwith the shoulder abductor 12 of FIG. 2. The integrated shoulder unit1416 locates the shoulder flexion axis 1426 and the abduction axis 1430relatively close to one another as compared to separate shoulder flexionand shoulder abduction assemblies, which provides for more intuitivemotion that more closely simulates the movement of a human shoulder.

The shoulder flexion drive 1424 and the abduction drive 1428 discussedabove include coaxial motors and coaxial shafts to minimize the size ofthe single shoulder unit 1416 and to reduce the weight thereof. Thus,these exemplary single shoulder unit 1416 is beneficial because itsweight relative to the separate shoulder abductor 12 and shoulderflexion assembly 14, shown in FIG. 2. Additionally, the single shoulderunit 1416 provides more narrow housing 1418, which allows a more naturalanatomical position of the shoulder for a broader range of users and mayreduce bumping with the user's residuum during use. embodiments have anadditional benefit of decreasing the weigh of the prosthetic.Additionally, as seen in FIGS. 43 and 44, both the abduction motor 1036and the shoulder flexion motor 1434 may be located in the vicinity ofthe electronics compartment 1432, so the electronics for both theshoulder flexion drive 1424 and the abduction drive 1428 may be locatedin the same place, which eliminates any need to route wiring through theshoulder unit 1416. This is advantageous since running wires acrossjoints is a failure mode in which the wires may crimp and break whenmoved. Thus, the shoulder unit 1416 eliminates this failure mode byeliminating wires running across the joints that could cause failure ofthe prosthetic arm 1010.

Although the shoulder flexion drive 1424 and the abduction drive 1428have been shown in an exemplary configuration, it should be understoodby those skilled in the art that other drive configurations may also beused to drive the single shoulder unit 1416 about the shoulder flexionaxis 1426 and the abduction axis 1445. For instance, referring to FIG.45, the shoulder flexion motor 2434 and the abduction motor 2036 do notneed to be coaxial and they may still each be located in the vicinity ofthe electronics compartment 2432. Additionally, rather than driving thelinkage 1444, shown in FIG. 43, the worm drive 2041 may insteadthreadably engage an abduction gear 2446 coupled to the harness mount2026, shown in FIG. 43, to generate pivotal movement about the abductionaxis 2430.

Additionally, referring now to FIG. 46, in various embodiments, theintegrated shoulder unit 3416 may shift the abduction output to changethe location of the harness mount 3026 to improve mounting locationand/or to allow for ninety degrees (90°) of abduction about theabduction axis 3430 without bumping with the residuum (not shown). Forexample, the location of the abduction output may be changed byextending the abduction drive 3428 with one or more additional shafts,gears, and/or belts.

Referring to FIG. 47, the flexion assembly mount 4030 may also beshifted away from the harness mount 4026 in the non-integrated shoulderabductor 4012. Referring to FIG. 48, the flexion assembly mount 4030 mayalso include an accommodating slot 4031 adapted to accommodate portionsof the abductor joint 4034, shown in FIG. 47. Referring back to FIG. 47,the shifted flexion assembly mount 4030 allows the user to orient theshoulder abductor 4012 on the prosthetic support apparatus (not shown)in different orientations while still allowing a range of motion of theshoulder abductor 4012 of at least approximately ninety degrees (90°).This may be particularly advantageous since the mounting orientation ofthe shoulder abductor 4012 may vary from user to user, which may limitthe range of abduction motion with the non-shifted flexion assemblymount 30, shown in FIG. 6. Additionally, in some embodiments, theshifted flexion assembly mount 4030 may house a flex sensor plunger fordetecting flexion motion of the shoulder flexion assembly 4014.

Referring now to FIG. 49, another embodiment of the wrist rotator 1020is shown for providing improved electronic wiring capability to theprosthetic device. Although shown as the wrist rotator 1020, it shouldbe understood by those skilled in the art that a similar configurationmay be used for other rotating joints, such as the humeral rotator 16,shown in FIG. 1. In this embodiment of the wrist rotator 1020, the wristrotator motor 1448, including the wrist rotator motor armature 1174 anda driven portion 1450 of the wrist rotator motor rotor 1176 having wristrotator magnets 1178 disposed thereon, and the wrist harmonic drivegearing system 1452, including the wrist rotator harmonic drive gearingsystem wave generator 1180, the wrist rotator harmonic drive gearingsystem flexspline 1182 and the wrist rotator harmonic drive gearingsystem circular spline 1184, are separated into coaxial side-by-sideunits with the wrist rotator motor 1448 being proximate to the elbowinterface 1170 and the harmonic drive gearing system 1452 beingproximate to the wrist flexion assembly interface 1172. By arranging thewrist rotator motor 1448 and the wrist harmonic drive gearing system1452 in the side-by-side configuration, the electronics channel 1190passing through the center of the wrist rotator rotor 1176 may be formedlarge enough to allow electronic wiring to be run internally through thecenter of the wrist rotator 1020. Referring to FIGS. 50 and 51, thewiring through the prosthetic arm 10, shown in FIG. 1, in someembodiments, may run through one or more extension springs 1454, inparticular around the flexion joints, such as the elbow flexion assembly18 and the wrist flexion assembly 22, shown in FIG. 1, where internalwiring is difficult or impractical.

Routing the wiring through the center of the wrist rotator 1020eliminates the need for external wiring, thereby minimizing any flexingmovement experienced by the wiring, which can cause wire pinching,abrasions and failure. The internal wiring also eliminates thepossibility that external wiring will become caught on something andbreak. Routing the wiring through the one or more extension springs 1454where internal wiring is not practical, possible or desired allows forcontrolled loading of the external wiring and protects the wiring frompinching to reduce wire failure.

Referring to FIG. 52, in another embodiment of the wrist flexionassembly 1022, the output arm 1196 is able to move in flexion relativeto the input support structure 1194 about a flexion axis 1456 and tomove in ulnar-radial deviation relative to the input support structure1194 about a deviation axis 1458. Thus, when the hand assembly 24, shownin FIG. 1, is attached to the output arm 1196 of the wrist flexionassembly 1022, the hand assembly 24, shown in FIG. 1, is able to move inboth flexion and ulnar-radial deviation.

Referring to FIG. 53, the wrist flexion assembly 1022 includes two wristmotors 1202, for controlling the flexion and ulnar-radial deviation ofthe output arm 1196, shown in FIG. 52. Each wrist motor 1202 drives aninput gear train 1460, which, in turn, drives a wrist worm gear 1462.Each worm gear 1462 drives an input gear 1464 of a wrist differential1466. The wrist differential 1466 includes a first bevel gears 1468 anda second bevel gear 1470 that are rotatable about the flexion axis 1456.The first bevel gear 1468 and the second bevel gear 1470 may be drivenby one of the input gears 1464. The wrist differential 1466 alsoincludes a differential body 1472 rotatably attached about the flexionaxis 1456 between the first and second bevel gears 1468 and 1470. Anulnar-radial axle 1474 extends from one side of the differential body1472 along the ulnar-radial axis 1458 and a third bevel gear 1476extends from the differential body 1472 on the opposite side thereof.The third bevel gear 1476 is rotatable about the ulnar-radial axis 1458and meshes with and is driven by the first bevel gear 1468 and thesecond bevel gear 1470.

In operation, the user is able to actuate wrist flexion, wristulnar-radial deviation and combinations thereof by actuating the motors1202 in various ways. For example, referring to FIG. 54, if the motors1202 are driven at the same speed in opposite directions, i.e. one isdriven clockwise and the other counterclockwise, the output arm 1196,shown in FIG. 52 will move in flexion in one direction about the flexionaxis 1456. If the direction of each motor is reversed, i.e. fromspinning clockwise to counterclockwise and vice versa, the output arm1196, shown in FIG. 52, will flex in the opposite direction. Similarly,referring to FIG. 55, if the motors 1202 are driven at the same speed inthe same direction, i.e. both are driven clockwise, the output arm 1196,shown in FIG. 52, will move in ulnar-radial deviation in one directionabout the deviation axis 1458. If the direction of each motor isreversed, i.e. from spinning clockwise to counterclockwise, the outputarm 1196, shown in FIG. 52, will move in ulnar-radial deviation in theopposite direction about the deviation axis 1458. In addition to varyingthe direction of rotation of the motors 1202, varying the speed of onemotor 1202 relative to the other will result in a combination of flexionand ulnar-radial deviation. Accordingly, in this embodiment, wristflexion and ulnar-radial deviation may both be controlled simply byvarying the direction and speed of the motors 1202.

Although the wrist flexion assembly 1022 is described as having adifferential drive 1466 for imparting wrist flexion and wristulnar-radial deviation movement to the output arm 1196, it should beunderstood by those skilled in the art that other drives may be used toachieve similar capabilities. For instance, referring to FIG. 56, thewrist flexion assembly 2022 may include a separate wrist flexion geartrain 2478 for imparting flexion motion to the output arm 2196 about theflexion axis 2456 and a separate ulnar-radial geartrain 2480 forimparting ulnar-radial deviation to the output arm 2196 about thedeviation axis 1458.

Referring to FIG. 76, in another embodiment of the present invention, awrist flexion assembly 4022 is provided for imparting a combination ofboth flexion about the flexion axis 4456 and ulnar-radial deviationabout the deviation axis 4458 to the hand assembly 4024 in a singlemovement. The wrist flexion assembly 4022 includes the input supportstructure 4194 adapted to be connected to the wrist rotator 20, shown inFIG. 1, in the same manner as discussed above. The wrist supportstructure 4194 includes a hand interface 4626 proximate to the handassembly 4024 for attaching the hand assembly 4024 to the wrist supportstructure 4194. The wrist support structure 4194 houses a wrist motor202, shown in FIG. 26, which drives the wrist pivot axle 4208 in rotarymotion about the wrist flexion axis 4456 through an appropriate geartrain (not shown). The wrist pivot axle includes flattened end portions4628 at each end thereof, extending outwardly from the wrist supportstructure 4194 and into the hand interface 4626. Each flattened endportion 4628 has two substantially parallel planar surface 4630extending parallel to the wrist flexion axis 4456. The hand interface4626 includes a first cam bearing 4632 fixedly secured to the wristsupport structure 4194 about the flattened end portion 4628 of the wristpivot axle 4208 proximate to the thumb structure 4220 of the handassembly 4024. The hand interface also includes a second cam bearing4634 fixedly secured to the wrist support structure 4194 about theflattened end portion 4628 of the wrist pivot axle 4208 proximate to thepinky finger 4230 of the hand assembly 4024. Referring to FIG. 77, thefirst cam bearing 4632 includes a first cam profile 4636 formed therein.Referring to FIG. 78, the second cam bearing 4634 includes a second camprofile 4638 formed therein. Referring back to FIG. 76, the handinterface 4626 also includes first and second slider blocks 4640coupling the hand assembly 4024 to the wrist flexion assembly 4022. Thefirst and second slider blocks 4640 each have a proximate end 4642 atthe hand interface 4626 and a distal end 4644 near the hand assembly4024. Each of the first and second slider blocks 4640 has a slot 4646formed therein that slidably receives one of the flattened end portions4628 of the wrist pivot axle 4208. The first and second slider blocks4640 include cam followers 4648 at their proximate ends 4642 that arereceived within the first cam profile 4636 of the first cam bearing 4632and the second cam profile 4638, shown in FIG. 78, of the second cambearing 4634. The first and second slider blocks 4640 are pivotallycoupled to the hand assembly 4024 at their distal ends 4644 about pivotaxes 4650.

In this embodiment, the hand assembly 4024 may be angled away from theflexion axis 4456 about a wrist rotation axis 4652 to reduce the motionthat the first cam profile 4636 and the second cam profile 4638 need toproduce to achieve the desired combined flexion and ulnar-radialdeviation movement of the hand assembly 4024. In some embodiments, thehand assembly 4024 is angled approximately thirty degrees clockwise (30°clockwise) assuming left hand user perspective from the flexion axis4456.

Referring to FIGS. 79A-79C, in operation, the wrist motor 202, shown inFIG. 26, drives the wrist pivot axle 4208 in rotation movement about theflexion axis 4456, which provides the hand assembly 4024 with flexionmovement. Additionally, the sliding engagement between the flattened endportions 4628 of the wrist pivot axle 4208 and the first and secondslider blocks 4640 causes the first and second slider blocks 4640 topivot about the flexion axis 4456 as the wrist pivot axle 4208 rotates.As the first and second slider blocks 4640 pivot, the cam followers4648, shown in FIG. 76, follow the first cam profile 4636, shown in FIG.76, and the second cam profile 4638, shown in FIG. 76, which causes thefirst and second slider blocks 4640 to slide relative to the wrist pivotaxle 4208. This sliding motion of each of the first and second sliderblocks 4640 causes the hand assembly 4024 to pivot about the pivot axes4650, shown in FIG. 76, which results in the ulnar-radial deviationmovement of the hand assembly 4024. Thus, as the wrist motor drives thewrist pivot axle 4208, the hand assembly 4024 moves from a firstposition 4654, shown in FIG. 79A, in which the hand is fully flexed anddeviated in the ulnar direction, to a second position 4656, shown inFIG. 79B, which is a neutral position with respect to flexion movementbut includes some degree of ulnar deviation. Then, the hand assembly4024 continues to move until it reaches a third position 4658, shown inFIG. 79C, in which the hand assembly 4024 is fully extended about theflexion axis 4456 and is also fully deviated in the radial direction.

Referring to FIG. 80, the first cam profile 4636, shown in FIG. 77, andthe second cam profile 4638, shown in FIG. 78, provide for movement ofthe hand assembly 4024, shown in FIG. 76, along a constrainedflexion-deviation movement path 4660 that includes components of bothflexion motion and ulnar-radial deviation motion. The constrainedflexion-deviation movement path 4660 is advantageous because the useronly needs to think about controlling a single degree of freedom, unlikethe embodiments discussed above that provide independent wrist flexionmovement and ulnar-deviation movement. Additionally, the constrainedflexion-deviation movement path 4660 is beneficial because it providesfor full flexion movement and also provides for nearly full ulnardeviation without requiring full wrist flexion. Thus, functionality isparticularly beneficial when users use the prosthetic arm apparatus 10,shown in FIG. 1, to pick up an object (not shown) from overhead. Theconstrained flexion-deviation movement path 4660 also advantageouslyallows for some degree of flexion movement without significant ulnardeviation, which allows the user to move an object, such as a spoon, inflexion motion without spilling its contents. This range of flexionmovement with minimal ulnar deviation provided by the constrainedflexion-deviation movement path 4660 may also be beneficial tocompensate for offset in situations where the prosthetic arm apparatus10, shown in FIG. 1, is mounted at an offset, for example, to avoid theuser's residuum. Additionally, since the hand assembly 4024, shown inFIG. 76, is angled in the neutral second position 4656, shown in FIG.79B, pinching of the thumb structure 4220, shown in FIG. 76, and indexfinger structure 4222, shown in FIG. 76, are more in line with the wristrotation axis 4652, which makes various tasks easier for the user, suchas turning a door knob, turning a key or the like. Thus, the constrainedflexion-deviation movement path 4660 provided by the wrist flexionassembly 4022, shown in FIG. 76, provides a variety of advantages overconventional prosthetic devices.

Although described in terms of constrained flexion-deviation movementpath 4660, it should be understood by those skilled in the art that thefirst cam profile 4636, shown in FIG. 77, and the second cam profile,shown in FIG. 78, may be formed in various configurations to achieve avariety of different constrained movement paths. Additionally, althoughthe constrained flexion-deviation movement path 4660 has been describedin connection with the wrist flexion assembly 4022, the constrainedflexion-deviation movement path 4660 may also be commanded using theflexion assembly 1022, shown in FIG. 52, by programming the prostheticcontroller to actuate the motors 1202, shown in FIG. 53, to move theprosthetic hand assembly 24 along the same constrained flexion-deviationpath 4660.

Referring to FIG. 57, in various embodiments, the non-backdriving clutch1070 may replace spacers of the input cage 1074 with springs 1482between the rollers 1072. The springs 1482 push the rollers 1072 apartand into contact with both the race 1078 and the output polygon 1484,which may be an output hex 1076. Thus, when a backdriving torque (notshown) is applied to the output hex 1076 to friction lock the rollers1072 between the output hex 1076 and the bearing race 1078, the rollers1072 are already contacting both the race 1078 and the output hex 1076,thereby eliminating backlash, i.e. a slight rotation of the outputpolygon 1076, when the backdriving torque (not shown) is applied. Thus,the non-backdrivable clutch 1070 imparts a frictional lock, whichadditional backdriving torque (not shown) through the output hex 1076will not overcome. Additionally, as discussed above in connection withFIG. 12, in various embodiments, the non-backdriving clutch 1070 mayunlock itself through the application of an input load through the inputcage 1074. Variations of this embodiment may include, but are notlimited to, additional or fewer springs 1482, additional or fewerrollers 1072 or a differently shaped race 1078. For example, in variousembodiments, the relative position of the output hex 1076 and the race1078 may be shifted, i.e., rather than the hollow, circular race 1078with the output polygon 1484 inside, in various embodiments, the clutchmay include an outer hollow output polygon surrounding a circular race.Additionally, although shown as a coil spring, it should be understoodby those skilled in the art that the springs 1482 may be formed invarious configurations and/or from a variety of metal or elastomericmaterials to provide the force for separating the rollers 1072.

Referring to FIG. 58, an embodiment for output load sensing through adrive 1486 having a worm gear 1488, such as the shoulder abduction drive1428 of FIG. 46, is shown. Including one or more worm gears 1488 in thedrive 1486 is beneficial because the worm gear 1488 may itself preventbackdriving. The worm gear 1488 may be arranged on a splined shaft 1490between a first spring 1492 and a second spring 1494. The splined shaftincludes a plurality of splines 1496 arranged axially around the surfaceof the splined shaft 1490 and a shaft input 1498 portion, which may berotated directly by a motor (not shown) or through a gear train or thelike. The worm gear 1494 is tubular and has an interior surface 1500designed to slidably interface with the splines 1496 of the splinedshaft 1490 such that the worm gear 1488 may slide axially along thesurface of the splined shaft 1490. The worm gear 1488 meshes with anoutput gear 1502 such that when the splined shaft 1490 is caused torotate through its shaft input portion 1498, the splined shaft 1490rotatably drives the worm gear #1488 through the splines 1496 which, inturn, drives the output gear 1502. When a load (not shown) is applied tothe drive through the output gear 1502, for example, if the user islifting an object, the load will generate a torque T at the output gear1502. Although the torque T will not cause the worm gear 1488 to rotate,the torque T may cause the worm gear 1488 to displace axially along thesplined shaft 1490 compressing one of the first spring 1492 or thesecond spring 1494, depending upon the direction of displacement. Thus,by designing the drive system 1486 with the first spring 1492 and thesecond spring 1494 of known spring constants, the compliance, i.e. thedisplacement of the worm gear 1488, may be measured to estimate theoutput load (not shown). This drive system 1486 for output load sensingis particularly beneficial since the compliance is still present oractive while the worm gear 1488 is not being rotated, but is insteadacting as a non-backdriving element.

The prevention of backdriving with the various systems discussed aboveis beneficial because it allows the user to maintain a position of theprosthetic arm 10, shown in FIG. 1, while under a load (not shown).However, referring to FIGS. 59 and 60, in some embodiments, it may bedesirable to provide the various arm segments with break-away mechanisms2504 that will separate the drive output from the drive input to preventdamage to the drive system if the load becomes too large. The break-awaymechanism 2504 may include an input shaft 2506, an output shaft 2508 andtwo break-away spacers 2510 that are held in contact with the inputshaft 2506 and output shaft 2508 by a compression member 2512. The inputshaft 2506 and the output shaft 2508 each include a shaft body 2514 anda torque transmission tab 2516 extending axially outward from the shaftbody 2514 between the break-away spacers 2510. The compression elementmember 2512 surrounds the break-away spacers 2510 and sandwiches thetorque transmission tabs 2516 therebetween. The compression member 2512may be, for example, a snap ring, a round metal ring, an o-ring,multiple o-rings, a coil spring, or the like. The compression member2512 applies a preset compressive force to the breakaway spacers 2510.

In operation, the input shaft 2506 of the break-away mechanism 2504 isrotated by a motor (not shown) or the like to generate a desiredmovement of the prosthetic arm 10, shown in FIG. 1. Thus, the torquetransmission tab 2516 of the input shaft 2506 rotates and transmits therotation through the break-away spacers 2510 to the torque transmissiontab 2516 of the output shaft 2508 as long as the torque required tocause rotation of the torque transmission tab 2516 of the output shaft2508 is not large enough to overcome the preset compressive forceprovided by the compression member 2510. If the torque is large enoughto overcome the preset compressive force, the torque transmission tab2515 will push the break-away spacers 2510 apart and the torquetransmission tab 2516 will rotate between the break-away spacers 2510without transmitting torque therethrough. Thus, the break-away mechanism2504 may prevent torque above a preset level from being transmittedthrough the drive system, where it can damage the drive systemcomponents. Accordingly, the break-away mechanism 2504 may limit theamount of torque applied to sensitive parts of the various drive systemsof the prosthetic arm 10, shown in FIG. 1, and may, therefore, impart alonger lifespan on the prosthetic arm.

Referring to FIG. 61A, another embodiment of a breakaway mechanism 3504includes an input ring 3518 and an output ring 3520 connected by adetent ring 3522. The breakaway mechanism 3504 may be connected betweentwo prosthetic arm segments, for example, the input ring 3518 may beconnected to the shoulder unit 1416, shown in FIG. 42, and the outputring 3520 may be connected to the humeral rotator 16, shown in FIG. 1.In some embodiments, the input ring 3518, output ring 3520 and thedetent ring 3522 each includes an alignment marker 3524 on its outersurface 3526 to indicate proper positioning of the breakaway mechanism3504.

Referring to FIG. 61B, the output ring 3520 includes a central hub 3528having an outer surface 3529 with a plurality of spring fingers 3530radiating therefrom. Each spring finger 3530 has a first detent 3532 anda second detent 3534 along its length and a pin 3536 at its distal end3538. The input ring 3518 includes a plurality of detents 3540 aroundthe circumference of its inner surface 3542, within which the pins 3536of the spring fingers 3530 may engage, as will be discussed in greaterdetail below. The detent ring 3522 includes a plurality of detent pins3544 located partway between the inner surface 3542 of the input ring3518 and the outer surface 3529 of the output ring 3520. The detent pins3544 engage the first detents 3532 of the spring fingers 3530 duringnormal operation of the breakaway mechanism 3504, i.e. when torque isbeing transmitted through the breakaway mechanism 3504.

However, referring to FIG. 62A, if an overtorque situation occurs, thepins 3536 at the distal ends 3538 of the spring fingers 3530 will popout of the ring detents 3540 so that the torque will not be transmittedback to the input ring 3504. Additionally, referring to FIG. 62B, theovertorque situation will also cause the alignment markers 3524 to moveout of alignment. The user may then realign the alignment markers 3524to transmit torque through the breakaway mechanism 3504.

Referring to FIG. 63A, the user may also intentionally disengage thetorque transmission by moving the alignment marker 3524 on the detentring 3522 up to engage the breakaway mechanism 3504 in freeswing. Asseen in FIG. 63B, this configuration entirely disengages the springfingers 3530 from the input ring 3518, thereby allowing the output ring3520 to rotate freely without driving the upstream components throughthe input ring 3518. Thus, this embodiment of the breakaway mechanism3504 is advantageous because it also allows for the user to engagefreeswing of the prosthetic arm 10, shown in FIG. 1.

These break-away mechanisms discussed above are beneficial because theyprevent damage to the prosthetic arm apparatus 10 due to high loadingsituations. Additionally, the break-away mechanisms are advantageous inthat once the break-away mechanisms break under high loading, they maybe reset by the user without the need to see a prosthetic technician.

As discussed above, various embodiments of the prosthetic arm 10, shownin FIG. 1, include feedback mechanisms, such as potentiometers forposition sensing. Referring now to FIG. 64, in some embodiments, theprosthetic arm 10, shown in FIG. 1, may include other feedbackmechanisms, for example, a magnetic position sensor 1546. In theseembodiments, at least one magnetic strip 1548 may be attached about thecircumference of an inner surface 1550 of a rotatable drive component1552. The magnetic strip 1548 includes a plurality of magnets 1554 ofknown length L1 arranged in series, each having a north pole N and asouth pole S. Thus, the magnetic strip 1548 generates a magnetic fieldhaving a repeating pattern of alternating north poles N and south polesS. The magnetic position sensor 1546 is arranged to detect this magneticfield generated by the magnetic strip 1548. In operation, the rotatabledrive component 1552 rotates, which causes the magnetic strip 1548 torotate, thereby moving the portion of the magnetic strip 1548 beingdetected by the magnetic position sensor 1546. The magnetic positionsensor 1546 detects this change in the magnetic field as the magneticstrip 1548 rotates from each north pole N to each south pole S and viceversa. Since the length L1 of each magnet 1554 is known, the detectedchanges in the magnetic field between each north pole N and/or eachsouth pole S may be converted into the distance of rotational movementof the rotatable drive component 1552. Thus, the change in position ofthe rotatable drive component 1552 may be detected. The magneticposition sensor 1546 is also advantageous because it does not contactthe rotating drive component 1552 and, therefore, will not experiencecontact wear due to the rotation of the rotatable drive component 1552.

Referring to FIG. 65, in some embodiments, two magnetic position sensors1546 may be used to detect the magnetic fields generated by the firstmagnetic strip 1548 and a second magnetic strip 1556 arranged next toeach other around the circumference of the inner surface 1550 of arotatable drive component 1552. A length L2 of each magnet 1558 of thesecond magnetic strip 1556 is, in some embodiments, different than thelength L1 of the magnets of the first magnetic strip 1548. Thisdifference in length allows for the magnetic position sensors 1546 tosense unique combinations of magnetic field values from the firstmagnetic strip 1548 and the second magnetic strip 1556 over thecircumference of the inner surface 1550. Each unique magnetic fieldvalue may correspond to a position of the drive component 1552 and,therefore, absolute position of the drive component 1552 may be detectedby the two magnetic position sensors 1546.

In practice, the hand assembly 24, shown in FIG. 1, and particularly,the fingers of the hand assembly 24, i.e. the thumb structure 220, indexfinger structure 222, middle finger 226, ring finger 228 and pinkyfinger 230, all shown in FIG. 3, come into contact with objectsfrequently and, therefore, may be susceptible to wear and damage. Thus,referring to FIG. 66, it may be desirable for the prosthetic handassembly 1024 to include removable fingers 1560. In this embodiment ofthe prosthetic hand assembly 1024, the removable fingers 1560 may beremoved to allow for easier replacement of damaged fingers 1560 andalso, to allow for easily customizable or tailored finger lengths fordifferent user.

Each removable finger 1560 is driven in substantially the same manner asthe fingers of the previously discussed embodiments. However, theremovable fingers 1560 pivot about a common finger shaft 1562, ratherthan the individual pivot axles discussed in connection with FIG. 33. Insome embodiments, end caps 1564 cover each end of the common fingershaft 1562 to prevent dirt or other contaminants from getting into thegear trains of the hand assembly 1024 and also to ensure that the commonfinger shaft 1562 does not become axially displaced unintentionally. Inoperation, either end cap 1564 may be removed from the hand assembly1024 and the common finger shaft 1562 may be extracted to free theremovable fingers 1560. Each finger 1560 may then be removed andreplaced individually, as required.

As discussed above, the fingers 1560 of the hand assembly 1024 come intocontact with objects frequently and are, therefore, susceptible to wear.Thus, referring to FIG. 67, some embodiments of the present inventionmay include a cosmesis 1566 for covering the hand assembly 1024 toreduce wear of the hand assembly 1024 and the fingers 1560, inparticular. The cosmesis 1566 may be formed from silicone or a similarmaterial, such as a urethane, to improve the grip capabilities of thehand assembly 1024 to assist with the various grasping and pinchfunctions of the hand, thereby, providing additional functionality.

In use, the cosmesis 1566 may wear more quickly around the fingers 1560and the thumb structure 1220. Therefore, in some embodiments thecosmesis 1566 may separate into two or more sections to allow high wearareas to be replaced more frequently than low wear areas. For instance,referring to FIG. 68A, in some embodiments, the cosmesis 2566 includes aseparate palm section 2568 covering the hand support 2218, fingersections 2570 covering each finger 2560 and a thumb section 2572covering the thumb structure 2220. Thus, the finger sections 2570 andthumb section 2572 may each be replaced separately from the palm section2568. Although shown as having separate finger sections 2570 and thumbsection 2572, in various embodiments, the cosmesis 2566 may also includeonly two sections, for example, the finger sections 2570 and the thumbsection 2572 may be combined into one section and the hand support 2218may be covered by the separate palm section 2568.

Referring to FIG. 68B, in some embodiments of the present invention, thefingers 3560 may be provided with geometric features 3574, such asslots, in their outer surfaces 3576 that may accept correspondinggeometric interlocks 3578 provided on the inner surface 3580 of thecosmesis 3566. This interlocking geometry may resist shear loads on thecosmesis 3566, thereby preventing the cosmesis 3566 from slipping off ofthe fingers 3560. Additionally, with respect to the hand cosmesis, finepinch and other functions may require a structural backing at the tipsof the fingers 3560 and thumb structure 3220. Therefore, in someembodiments, the geometric features 3574 of the fingers 3560 and thumbstructure 3220 may each include a fingernail apparatus 579, shown inFIG. 40. The fingernail apparatus 579, shown in FIG. 40, interacts withthe finger and thumb structure cosmesis 3566 to anchor the cosmesis 3566of the fingers 3560 and thumb structure 3220, thereby mitigating and/orpreventing the cosmesis 3566 from rolling over on the tips of thefingers 3560 and thumb structure 3220.

Referring to FIG. 69, the palm section 1568 of the cosmesis 1566 mayalso be formed to resist slippage due to shear loads. For instance, apalm side 1582 of the cosmesis 1566 may be formed with a tacky innersurface 1584. In some embodiments, the material of the cosmesis 1566itself will provide the tacky inner surface 1584, for example, siliconor a urethane material may be naturally tacky. In other embodiments, atacky surface coating may be applied to the cosmesis to form the tackyinner surface 1584. Thus, as objects being held are pressed against thepalm side 1582 of the cosmesis 1566, the tacky inner surface 1584 ispressed against the hand support 1218, shown in FIG. 29, therebyresisting slippage. In some embodiments, in this embodiment, a back side1586 of the cosmesis 1566 is formed with a slippery inner surface 1588to facilitate installation and removal of the cosmesis 1566. Forexample, the slippery inner surface 1588 may be formed by applying asurface modifying coating to the cosmesis, or applying a surface textureto the cosmesis 1566. For example, to install the cosmesis 1566 onto thehand support 1218, shown in FIG. 29, the cosmesis 1566 may be pulleddown and away from the palm so that the slippery inner surface 1588 ofthe back side 1586 slides along the hand support 1218, while the tackyinner surface 1584 of the palm side 1582 is pulled away from the handsupport 1218. Thus, the cosmesis 1566 may be easily slid onto the handsupport 1218. To remove the cosmesis 1566, the palm side 1582 may againbe pulled away from the hand support 1218 while the cosmesis 1566 ispulled toward the fingers 1560, thereby allowing the cosmesis 1566 toslide easily off the hand support 1218.

Additionally, in some embodiments, the fingers 1560 may include one ormore additional functions. For example, referring to FIG. 70, one ormore fingers 1560 may include a thermal sensor 1590 disposed thereon todetermine the temperature of an object (not shown) brought into contactwith the finger 1560. The signal from the sensor 1590 may be transmittedto a controller (not shown) for the prosthetic arm 1010 and displayed tothe user as will be discussed in greater detail below. In someembodiments, temperature detection may be provided by forming thecosmesis 1560, or a portion thereof, from a temperature sensitivepolymer, such as a polymer with a thermochromic color changing additivetherein or thermochromic liquid crystal that allows a variety of colorsto be shown as temperature changes, which will change color dependingupon the temperature of the cosmesis 1566. For example, the cosmesis1566 may change from one color to another if a present temperature isexceeded. This temperature sensing functionality may be used todetermine the temperature of an object (not shown) in the hand 1024 andto warn the user of a high temperature or low temperature condition tomitigate the threat of burns or other harm.

Referring to FIG. 71, another embodiment of the thumb structure 2222 isshown for providing thumb compliance detection. The thumb structureincludes a thumb base 2592 and a thumb tip 2594, which are eachsubstantially rigid and are joined together by an elastomeric spring2596. In some embodiments, the interface between the thumb tip 2594 andthe elastomeric spring 2596 includes one or more alignment features 2598to ensure proper alignment of the thumb tip 2594 with the elastomericspring 2596. Similarly, the interface between the thumb base 2592 andthe elastomeric spring 2596 also includes one or more alignment features2598 to ensure proper alignment of the thumb base 2592 and theelastomeric spring 2596.

Referring to FIG. 72, within the thumb structure 2222, the thumb base2592 includes a pivotal interface tube 2600 extending upward into acentral bore 2602 of the elastomeric spring 2596. A pivot shaft 2604,having a magnet 2606 disposed at its lower end 2608, is arranged withthe pivotal interface tube 2600 and extends upwardly therefrom into acentral bore 2610 in the thumb tip 2594 of substantially the samediameter as the pivot shaft 2604. Below the pivot shaft 2604 within thethumb base 2592 is arranged a Hall effect sensor 2612 on a sensorbracket 2614. The sensor bracket 2614 includes a wire channel 2616 tofacilitate wiring the Hall effect sensor 2612 to the prosthetic controlcircuits (not shown). Referring to FIG. 73, in operation, when a load Lis applied to the thumb tip 2594 the elastomeric spring 2596 compresseson the side of the thumb structure 2222 opposite the applied load L,allowing the thumb tip 2594 to tilt. The tilt of the thumb tip 2594causes a corresponding tilt of the pivot shaft 2604 within the pivotalinterface tube 2600, thereby displacing the magnet 2606 disposed on thelower end 2608 of the pivot shaft 2604. The Hall effect sensor 2612detects this displacement of the magnet 2606, which can be correlated tothe applied load L on the thumb tip 2594. By detecting the various loadson the thumb structure 2222, the user may ensure that objects are notgripped so hard that they could break and that the thumb is notsubjected to loads that could cause failure of the thumb structure 2222.

Referring to FIG. 74, in some embodiments, the humeral rotator 1016 mayinclude a yolk 1618, rather than the cantilever mounting interface shownin FIG. 16, for interfacing with the elbow flexion assembly 1018. Theyolk 1618, interfaces with a first side 1620 and a second side 1622 ofthe elbow flexion assembly 1018 to provide increased strength to theinterface when compared to the cantilever mounting interface shown inFIG. 16, which only interfaces with one side of the elbow flexionassembly 1018.

Referring to FIG. 75A, in some embodiments of the present invention, theprosthetic arm 3010 may be provided with a status indicator 3620. Insome embodiments the status indicator 3620 may include, but is notlimited to, one or more LEDs 3622 arranged on the hand assembly 3024.However, in other embodiments, the one or more LEDs 3622 may be locatedin various locations. The one or more LEDs 3622 may be configured tocommunicate a variety of information to the user, including, but notlimited to, one or more of the following, battery power level, anoperational mode of the prosthetic device, faults, alarms, alerts,messages, and/or the like. Additionally, although shown as one or moreLEDs 3622 the status indicator 3620 may, in other embodiments, include adigital display and/or user interface, which may be arranged on theprosthetic device 3010, built into the prosthetic device 3010 and/or maybe a separate display unit (for example, as shown in FIG. 75B as 3630),and in some embodiments, may be a unit worn similarly to a wrist watchor bracelet as shown in FIG. 75B as 3630. However, in other embodiments,the unit 3630 may be a portable unit that may be worn or carried nearthe user, for example, but not limited to, clipped on clothing, beltand/or attached to the user, and/or carried in a pocket either in theuser's clothing and/or in a separate bag and/or pack. In someembodiments, the unit 3630 may be a PDA (personal data assistant), smartphone or other electronic device configured to communicate with theprosthetic device 3010 by way of a wireless communications protocol,including, but not limited to, RF and Bluetooth®.

Thus, in some embodiments, it may be desirable to include both aseparate display unit and one or more LEDs 3622, where, for example, butnot limited to, the one or more LEDs 3622 may be used to display one ormore critical piece of information to the user, while the separatedisplay unit, 3630 may provide a greater variety of information in moredetail.

Still referring to FIG. 75, in some embodiments of the presentinvention, the prosthetic arm 3010 may be provided with an emergencyswitch 3624 which may turn off power to the system and thus engage thevarious brakes and/or clutches in the prosthetic arm 3010. In someembodiments, the emergency switch 3624 is a chin switch that the usermay activate with their chin.

The prosthetic arm apparatus of the present invention has a variety ofbenefits over conventional prosthetic devices, such as the modularity ofeach segment of the prosthetic arm apparatus as discussed above, whichallows the formation of customized prosthetic devices for differentusers. In particular, each segment of the prosthetic arm apparatus 10contains all of the actuators for that segment so that it may be removedas a separate unit. For instance, the hand assembly includes all of thefinger actuators therein, allowing it to be connected and/or removed asa separate unit. Additionally, various degrees of freedom of the handassembly are particularly beneficial because they allow the formation ofvarious grasps or grips.

Exoskeleton System and Apparatus for Robotic Device

Referring now to FIGS. 81 and 82, an exemplary embodiment of theexoskeleton system may include an exoskeleton apparatus 8100, at leastone robotic device 8102, 8104, which, in the embodiment shown, may berobotic arms 8102, 8104. In some embodiments, the system may include astructure 8106 for attaching the one or more robotic devices 8102, 8104.In the exemplary embodiment shown, the structure 8106 may be a mobileplatform/mobile structure 8106 which may include one or more wheels8108. In some embodiments, the mobile platform/mobile structure mayinclude the a device, apparatus and/or control scheme as described inU.S. Pat. No. 5,971,091 issued Oct. 26, 1999 and entitled TRANSPORTATIONVEHICLES AND METHODS; U.S. Pat. No. 6,223,104, issued Apr. 24, 2001 andentitled “FAULT-TOLERANT ARCHITECTURE FOR PERSONAL VEHICLE”, both ofwhich are hereby incorporated herein by reference in their entireties.Although an exemplary embodiment is referred to herein, this is merelyfor illustrative purposes only. Additional embodiments are contemplatedand discussed and the devices, system and apparatus are not limited tothe embodiments shown as the exemplary embodiments.

In the exemplary embodiments, the robotic arms 8102, 8104 are attachedto the mobile platform 8106 by attachment via a compliant member 8110.In some embodiments, the compliant member 8110 may be made from acompliant materials, e.g., polyurethane, which may be desirable forpolyurethane includes compliance in all directions, i.e., “3Dcompliance”, as well, polyurethane has damping properties which may bedesirable in some applications. However, in other embodiments, thecompliant member 8110 may be another member, for example, but notlimited to, one or more of the following: a metal spring or othercompliant material, means, assembly and/or device. Referring to FIG. 83,one embodiment of the attachment is shown. In this embodiment, therobotic assembly 8302 attaches to the complaint member 8300 and thecompliant member 8300 attaches to the platform 8304. A bolt 8308 may beused as an attachment point for the robotic assembly 8302, the compliantmember 8300 and the platform 8304. A nut 8306 may be used, in someembodiments, to stabilize/maintain the bolt 8308.

Referring to FIG. 81, in some embodiments, including the embodimentshown in FIG. 81, the exoskeleton may be worn by a human 8112 by way ofan attachment system which may include a series of straps 8114, 8116,8118. In some embodiments, the straps 8114, 8116, 8118 may be adjustable(as shown in FIG. 81), however, in other embodiments, one or more straps8114, 8116, 8118 may not be adjustable. In some embodiments, theattachment system may be customized to the user and thus, adjustabilitymay not be necessary. However, in some embodiments of the customizableembodiments, one or more straps may be adjustable. With respect toadjustable straps 8114, 8116, 8118, these may be adjusted along the hipsof the user using a hip strap 8114, the torso of the user using shoulderstraps 8118 and chest strap 8114 and the distance between the back ofthe user and the top of the exoskeleton may be adjusted using the uppertorso straps 8118. In some embodiments, the attachment system may besimilar to one found on an ergonomic backpack for example, in theexemplary embodiment, the backpack strap system from Trekker 3950backpack made by KELTY®, Boulder Co., USA, may be used as the attachmentsystem. In some embodiments, the exoskeleton 8100 is removable. Invarious embodiments, the exoskeleton attachment system may include fewerstraps than shown and described herein with respect to the exemplaryembodiments and/or in some embodiments, the exoskeleton may includeadditional straps than shown and described herein with respect to theexemplary embodiments. For example, in some embodiments, the exoskeletonmay include a lower body component and thus, may include differentand/or additional straps adapted to removably or nonremovably attach tothe user's lower body. For example, to attach to their hip, upper leg,knee, lower leg, ankle and/or foot. In some embodiments, the exoskeletonmay be a lower body exoskeleton and may not include an upper bodyportion.

Referring now to FIGS. 84A-84D, isometric, front, back and side views ofone exemplary embodiment of the exoskeleton are shown. In addition tothe straps discussed above, the exoskeleton, in some embodiments, mayinclude an exoskeleton frame which may include a lower portion 8400 andan upper portion 8402. In some embodiments, the upper portion 8402 maybe telescopingly connecting to the lower portion 8400 such that theframe is adjustable. As shown in 84C, in some embodiments, theadjustability may be in the form of a ball detent mechanism 8404 and mayinclude one or more adjustable sizes. As shown in one embodiment, theadjustability may include seven sizes. As discussed above, in someembodiments, the frame may be a backpack frame, for example, a Trekker3950 backpack made by KELTY®, Boulder Co., USA. In various embodiments,the adjustability mechanism may vary and, in some embodiments, the framemay not include adjustability and may be customzably sized and/or may bemade based on the size of the intended user. In some embodiments, theframe may be made to average sizes of intended users.

In some embodiments, the frame may be made from aluminum. However, insome embodiments, the frame may be made from one or more plasticmaterials, stainless steel, magnesium or any other material that may beused to make a frame such as one of the embodiments discussed herein.

Still referring to FIGS. 84A-84D, in some embodiments, the hip strap8114 may be adjustable with respect to the distance from the top of theframe to the hip strap 8114 as well as adjustable with respect to thecircumference of the strap. In some embodiments, the adjustabilityfeature with respect to height may be a ball detent mechanism 8406.

In some embodiments, the exoskeleton may include a support structure8408 which may also serve as a handle for carrying the exoskeletonand/or for user mounting the exoskeleton either alone or withassistance.

Described herein are various sensors and feedback mechanisms which maybe used to both control at least one robotic assembly and also, in someembodiments, to provide feedback regarding the at least one roboticassembly to the user. In some embodiments, where at least one sensor isused, the at least one sensor and, in embodiments including at least onefeedback mechanism, the at least one feedback mechanism, may communicatevia electronic wiring, i.e., they may be hardwired. However, in otherembodiments, at least one of the at least one sensor and/or the at leastone feedback mechanism may be wirelessly connected, i.e., via at leastone form of wireless communication.

With respect to the exemplary embodiment shown in the various figures,the system includes a hard wired embodiment. In the exoskeleton, thewires are contained within a wiring housing 8410, 8412 to organize thewires. This embodiment may be desirable to preventaccidental/unintentional catching of the wires on an object and or toprotect the wires from breakage and tangling. In some embodiments, asshown in the various figures, there may be one or more wiring housing8410, 8412, and, in some embodiments, there may be more than two wiringhousings. In some embodiments, the wiring housing 8410, 8412 may be madefrom any material desired, however, in the exemplary embodiments, ismade from a flexible plastic. However, in other embodiments, may be madefrom other materials, including, but not limited to, rigid or flexiblematerials.

The wiring housing 8410, 8412 is connected to the exoskeleton through awire connection 8414, 8416. In some embodiments, there may be one wireconnection, however, in other embodiments; there may be more than onewire connection, as shown in the exemplary embodiment. The wireconnection 8414, 8416, is, in some embodiments, a housing for the wiresthat run through the wiring housing 8410, 8412, to connect to a point onthe exoskeleton. The wire connection 8414, 8416 may be made from anymaterial desired, but in some embodiments, may be made from a metal,e.g., aluminum or stainless steel, or a plastic.

Referring also to FIGS. 85A-85B where isometric views of a shoulder, armand hand portion of one embodiment of the exoskeleton are shown. Inthese views, the shoulder, arm and hand portion has been broken awayfrom the exoskeleton apparatus shown in previous figures. Together withthe previous figures, exemplary embodiments of the arm and hand portionsare described below.

Various embodiments of the exoskeleton rely on mapping movement by theuser to movement by the at least one robotic assembly. Thus, it iscritical that the movement of the user be sensed appropriately to mapthe movement to the at least one robotic assembly. For purposes of thedescription of the exemplary embodiments, the description will refer tothe at least one robotic assembly as “robotic assemblies”. However, itshould be understood that in various embodiments, one robotic assemblymay be used.

In some embodiments, gross movements by the user may be translated bythe shoulder. Thus, the rotation points of the shoulder of the user arecritical to map correctly in these embodiments. To do so, it may benecessary to determine the center point of the shoulder thus determiningthe center point of rotation of the shoulder. However, finding thecenter of rotation of a shoulder of a user may be difficult. Also, usersmay have different centers of rotation of the shoulder. Thus,adjustability of the exoskeleton is critical to mapping the center ofrotation of the shoulders correctly to thus translate to true mapping ofthe gross movements of the user to the robotic assemblies.

Still also referring to FIGS. 85A-85B, in the exemplary embodiment, theexoskeleton shoulder and arm portions are essentially located on twoplanes. In the exemplary embodiment, through various adjustabilityfeatures, the lengths of the exoskeleton from the spine area of the userto the shoulder as well as the length of the exoskeleton from theshoulder to the elbow, the elbow to the wrist, are adjustable.

In the exemplary embodiment, the exoskeleton shoulder portion includesat least two sensors 8510, 8512, which, in some embodiments, arepotentiometers. The type of potentiometer may be any potentiometer,including but not limited to, a linear potentiometer. In variousembodiments, at least one potentiometer is used to measure/senseshoulder abduction and at least one potentiometer is used tomeasure/sense shoulder flexion. In some embodiments, the system may usetwo different potentiometers to measure the shoulder abduction andshoulder flexion, and in some embodiments, the system may use the samepotentiometers to measure both motions. In the exemplary embodiment,each joint of the user's arm/shoulder includes at least onepotentiometer to measure the amount of rotation. The signal data fromthe potentiometers is used by the control system (described below) tomap movement to the robotic assemblies.

In the various embodiments, to fit the exoskeleton to a user, one goalis to adjust and/or design the exoskeleton for a particular user suchthat the center axis of rotation of each shoulder potentiometer meets inthe center of the ball joint of the user's shoulder.

In various embodiments, to assist in adjusting the exoskeleton such thatthe center axis of the potentiometers meets in the center of theshoulder ball joint of the user, ball joints 8514, 8516 are included inthe exoskeleton. It should be understood that in the exemplaryembodiments of the exoskeleton, there are two ball joints for each arm(shoulder, hand), thus, in the exemplary embodiments, there are fourball joints on the exoskeleton. However, in various embodiments, theremay be more than four or less than four ball joints. Also, in variousembodiments, components accomplishing the same functionality asdescribed with respect to the ball joints may be used.

In the exemplary embodiment, the ball joint used is a RAM® mount such asone made by National Products Incorporated, Seattle, Wash., USA. Usingthese ball joints 8514, 8516, the exoskeleton may be adjusted such thatthe length and orientation/angle of the back portion 8502 and the sideportion 8504 of the exoskeleton may be adjusted. Thus, the exoskeletonmay be adjusted to fit a user such that the axis of rotation of thepotentiometers 8510, 8512 meet in the center of the user's shoulder balljoint.

With respect to the ball joint located on the back of the frame 8514, insome embodiments, including the exemplary embodiment, a compliancesection 8518 may be included to allow for sternoclavicular motion by theuser. Thus, with the compliance section 8518, the user may move theirarms forward and having compliance in the joint. The compliance section8518, in the exemplary embodiment, may be a torsion spring which springsback the user stops movement in the forward direction. This allowsarticulation and the torsion spring 8518 automatically pulls theexoskeleton back. The torsion spring 8518, in some embodiments, may beset such that the user may overcome the spring when forward movement isdesired and the spring pulls the exoskeleton back in a light fashionsuch that the user may not notice.

In the exemplary embodiment, the spring constant of the torsion spring8518 may be 0.014 inch pounds per degree. Also, in the exemplaryembodiment, the torsion spring 8518 may produce a torque of 5.15 inchpounds at 360 degrees of rotation with a preload of approximately 2.5inch pounds. Additionally, in some embodiments, the torsion spring 8518may be preloaded with a hard stop. The hard stop may be adjustable tothe user such that the torsion spring 8518 is limited in how far it maypull the exoskeleton back. In some embodiments, this adjustment may bemade at the time of initially using the exoskeleton. In someembodiments, this may be accomplished where the user rolls theirshoulder back and the hard stop is adjusted to that position. In someembodiments, the adjustment may be made using a knob, however, in otherembodiments; the adjustment may be made using anything that may adjustthe hard stop. In the exemplary embodiments, the hard stop may bedesirable to maintain the flexion joint in the correct place where theshoulder ball joint may be accurately tracked.

Still referring to FIGS. 85A-85B, in the exemplary embodiment, theexoskeleton includes at least one tactor motor to provide feedbackregarding the robotic assemblies to the user. In some embodiments, theat least one tactor may be connected to the exoskeleton by a strap whichmay be strapped to the user using a tactor strap 8518 such that thetactor motor 8520 may be in close proximity to the user such that theuser may feel signals from the tactor motor 8520. In the exemplaryembodiment, the tactor strap 8518 may be an adjustable strap which may,in some embodiment, attach to itself by way of a hook and loop fasteningsystem. However, in other embodiments, a buckle system, clip system orany other attachment or fastening mechanisms may be used. In someembodiments, the strap may not be adjustable, however, in the exemplaryembodiment, the strap is adjustable.

In the exemplary embodiment, the at least one tactor motor 8520 may be avibration motor or other motor that may provide a signal to the user. Inthe exemplary embodiments, at least one or the at least one tactor motor8520 provides feedback to the user related to the torque of the shoulderand elbow joint of the robotic assembly. In the exemplary embodiment,the user may wear two tactor motors 8520, one on each arm, eachproviding feedback from one robotic assembly.

Thus, the at least one tactor motor 8520 receives input from at leastone joint on the at least one robotic assembly. For example, in theexemplary embodiments, the at least one tactor motor 8520 receives inputfrom the compliance measurements on the robotic arm. In someembodiments, however, the at least one tactor motor 8520 may receiveinput from one or more compliance sensors which may be in the compliantmember 8110. In some embodiments, four or more compliance sensors may beon the compliant member 8110 and thus provide directional feedback, viaat least one tactor motor 8520, regarding the direction of force beingimparted on to the robotic arms/assembly. In various embodiments of thisembodiment, the user may wear four tactor motors to receive input infour directions. Thus, in some embodiments, where the user may not beable to see the robotic assembly, this may be desirable to determine thedirection where there may be an object or wall and thus, navigate awayfrom a problematic area.

In some embodiments, the feedback is proportional to the average of thetwo, and in other embodiments, may be the sum of the two, etc. However,in the various embodiments, the feedback relates to gross overall armmotion and whether or not the robot assembly may have hit anything or isjammed up against a structure/wall or other. Thus, in some embodiments,this feedback may indicate to the user if one or more of the roboticassemblies are jammed, stuck, etc. The tactor motor 8520 may alsoprovide feedback related to how hard the robotic assembly is pushing onsomething which may be useful in controlling the robotic assemblies andcompleting one or more tasks. In some embodiments where a vibrationmotor is used, the intensity of the vibration may be proportional to thetorque. In some embodiments, however, an auditory feedback may be used,which may include, but is not limited to, feedback where a single toneis given, the higher the tone, for example, the higher the torque. Inother embodiments, one or more lights, for example, one or more LEDs,may be used, and this may include variations including, but not limitedto, one or more of the following: using blinking/on/off patterns and/orcolor to indicate feedback to the user.

Still referring to FIGS. 85A-85B, the exoskeleton between the shoulderand the elbow and between the elbow and the wrist may, in someembodiments, be adjustable. In the exemplary embodiment, a telescopingfeature may be used for adjustment of the upper arm 8504 and lower armportions 8522, 8524. In some embodiments, a mechanism similar to acamera tripod adjustability feature may be used. In some embodiments,the tripod-like mechanism may be desirable for its ability to lock inplace easily and include a strong locking mechanism as well as itsability to open and close easily. However, in various other embodiments,any mechanism allowing for adjustability may be used. By using thevarious adjustability features, the location of the wrist joint andelbow joint of the exoskeleton may be adjusted to be proximate to thelocation of these joints on the user. Similarly as with the shoulderjoint, the accuracy of the control of the robotic assemblies using theexoskeleton will depend partly on the exoskeleton's ability to map themovement of the user's joints, which may be improved with the one ormore sensors being located proximate to the user's joints. The movementof the user may be mapped using at least one sensor for each user joint.In addition to the ones discussed above with respect to the shoulderjoints, in the exemplary embodiments, the exoskeleton includes at leastone potentiometer 8526 on the elbow joint and at least one potentiometer8528 on the wrist joint which may sense wrist rotation and may bereferred to as the wrist rotation sensor 8528. It should be understoodthat although in some embodiments, potentiometers are used, in otherembodiments, various other sensors may be used to track the movement ofthe joints. These sensors may include, but are not limited to, IMUs(inertial measurement units), which, in some embodiments, may be one ofthe IMUs described in International Publication No. WO 2010/120403 A2 toVan der Merwe et al. on Oct. 21, 2010 and entitled “System, Method andApparatus for Control of a Prosthetic Device”. However, in otherembodiments, the sensor may be any sensor, including but not limited to,bend sensors.

The elbow joint and wrist joints are formed from a series of rings.These are referred to as the humeral and wrist rotators. In theexemplary embodiments, the humeral and wrist rotators rotate with theuser's humeral and wrist rotation. Additionally, in some embodiments,where there may be limitations of movement inherent in the one or morerobotic assemblies being controlled using the exoskeleton, thoselimitations may be built into and/or reflected in the movement of theexoskeleton. In this way, the user may be limited in motion in theexoskeleton, however, this may lead to more accurate control of the oneor more robotic assemblies as the user will not expect or intend for therobotic assembly to move in a way that the user can not move while usingthe exoskeleton. Thus, in some embodiments, there may be one or morestops built into the joints at particular/predetermined locations whichprevent the user from commanding the robotic assembly to move in a wayit is not able to move. In some embodiments, the stops may also preventthe exoskeleton from being tangled.

In the exemplary embodiment, the humeral and wrist rotators may besimilar. In the exemplary embodiments, the rotators include large thinring bearings, which, in some embodiments, may be KAYDON bearings, oranother similar bearing. These large thin ring bearings allow acantilever mode to account for moment loads. Also, the rotators includea ring spur gear that go to a pinion gear attached to thesensor/potentiometer. However, as discussed above, in other embodiments,the sensor may a sensor other than a potentiometer and in someembodiments; the joint may include more than one potentiometer.

In some embodiments, such as the ones shown in the exemplary embodiment,the stops may be a plate with protrusions that protrudes from the platethat act as stops so that the user may not command the robotic assemblyto go past where the robotic assembly can move. In some embodiments, thestops may be adjustable such that the exoskeleton may be used withdifferent robotic assemblies. However, in some embodiments, the stopsare nonadjustable and are designed to be used with specific roboticassemblies.

In some embodiments, as in the exemplary embodiment, the exoskeleton mayinclude a feature such the area between the humeral and wrist rotatorsmay rotate. This may be desirable for when a user extends their arm inthe exoskeleton, their arm rotates. Thus, the exoskeleton, in someembodiments, also rotates to a second position to map the user's arm.However, in some embodiments, when the exoskeleton rotates, there is areturn mechanism 8530 to rotate the area between the humeral and wristrotator back to its original/starting/first position. In someembodiments, the return mechanism 8530 includes a pulley and a bungeewrapped about the pulley inside a housing. The bungee may be anchored tothe humeral joint. Thus, in these embodiments, when the user rotates thehumeral and wrist joint, this loads the bungee and the pulley/bungeesystem pull the joints back from the second position such that thejoints rotate to the starting/original/first position.

In the exemplary embodiment, the wrist rotator is constructed in asimilar fashion as the humeral rotator. However, in the exemplaryembodiments, the wrist rotator has a smaller diameter and does notinclude a return mechanism. However, in various embodiments, thediameter of the wrist rotator may be the same as the humeral rotator.Also, in some embodiments, a return mechanism may be included on thewrist rotator.

Referring now to FIGS. 86A-86B, as well as FIGS. 86C-86G, theexoskeleton, in some embodiments, may include a hand portion 8600 whichincludes the wrist rotation portion including the wrist rotation sensor8528. In the exemplary embodiments, the hand portion 8600 may include aglove plate 8602. In the exemplary embodiments, the user may place theirhands in a glove 8604. The glove 8604, in the exemplary embodiment,includes a thumb splint 8606, an index finger sensor 8608 and a middlefinger sensor 8610. In some embodiments, and as shown in FIGS. 86A-86B,the index finger sensor 8608 and a middle finger sensor 8610 may beincluded on the same body 8612. In some embodiments, any glove may beused and attached to the glove plate 8602. In the exemplary embodiment,the glove plate 8602 may include various holes for attachment of theglove 8604 (the hole features may also be seen in FIGS. 86C-86G). Thevarious holes allow for attachment of various sized gloves toaccommodate different sized users. However, in some embodiments, theglove plate 8602 may not include adjustability features.

In some embodiments, the sensors 8612 and thumb splint 8606 areconnected to the exoskeleton and may fit into pockets 8614, 8616, 8618on the glove 8604. In the exemplary embodiments, the thumb splint 8606includes at least two sensors 8620, 8622, which, in some embodiments,may be potentiometers. In the exemplary embodiments, the sensors 8616,8618 are flexible bend sensors such that the sensors detect when theuser bends their index or middle fingers. The bend sensors 8616, 8618send signals, through an electrical connection, to a control system(described below). In various embodiments, the bend sensor may detectbend using resistance change data. Thus, in some embodiments, thefurther the user bends their finger, the more the resistance changes,thus indicating movement. In various other embodiments, additionalsensors may be included on the middle, ring and pinky fingers. However,in the exemplary embodiment, these sensors may not be necessary as thecontrol system works to control a robotic hand/arm and that robotic handarm includes a hand in which the middle, ring and pinky move together.However, in other embodiments, where various robotic assemblies may becontrolled using the exoskeleton, different sensors may be used andselected based on the robotic assembly functionality and the controlsystem thereof.

As discussed above, the exemplary embodiment includes a thumb splint8606. In the exemplary embodiments, the thumb splint 8606 limits themovement of the user's thumb. It may be desirable, as discussed withrespect to the stops discussed in the joint rotators above, to limitmovement of the user where the robotic assembly the exoskeleton controlsincludes limited movements. Thus, in the exemplary embodiment, theexoskeleton controls two robotic arms/hands/shoulders (collectivelyreferred to as a “robotic arm”). In some embodiments of the robotic arm,the robotic thumb includes specifically programmed movements. Thus, theexoskeleton includes a thumb splint 8606 to limit the user's thumbmovements to those that are included in the robotic thumb's programmedmovements. Although herein are some examples of limited movements in theexoskeleton to mimic the limited movement of the robotic assembly, theseare not an exhaustive list. In various embodiments of the exoskeleton,mechanical features may be added to the exoskeleton to limit themovements of the user to match and/or mimic the allowed/possiblemovements of the robotic assembly. However, in some embodiments, asdiscussed in more detail below, the robotic assembly may includeadditional capabilities that the user may not accomplish. Thus, in someembodiments, although stops may be used to limit the movement of theuser, the control system may allow for additional and expanded/continuedmovement of the robotic assembly.

With respect to the robotic arm controlled by the exoskeleton in theexemplary embodiment, the thumb includes two degrees of freedom, yaw andpitch. Thus, the exoskeleton includes two potentiometers 8620, 8622, oneto sense yaw, one to sense pitch, which sense the movement of the thumbsplint 8606 and provide signals to the control system map the movementof the robotic arm's thumb. In other embodiments, additional sensors ordifferent sensors may be used. In some embodiments, a single sensor maybe used.

In some embodiments, the exoskeleton hand or the glove may include atactor motor 8624. In some embodiments, the tactor motor on the glove orthe exoskeleton hand is located such that the user may see, feel or hearthe tactor. In some embodiments, the tactor motor is a vibratory motor.However, in some embodiments, the tactor may be an auditory tactor. Inother embodiments, the tactor is a visual tactor and may include one ormore lights, e.g., LEDs, which may indicate/signal to the user viablinking, on/off, and/or colors, to indicate various feedback to theuser. In the exemplary embodiment, the tactor motor is a vibratory motorand provides feedback to the user with respect to the thumb gripstrength of the robotic arm. Although in the exemplary embodiment, thethumb tactor is located on the glove or hand portion of the exoskeleton,in some embodiments, the tactor may be located elsewhere on theexoskeleton. In some embodiments, the tactor may be located on a strapand/or on a separate device containing one or more feedback indicatorsto the user. For example, in some embodiments, the tactor may be anindicator as described in WO 2010/120403 A2.

In some embodiments, the exoskeleton may include an inertial measurementdevice and/or potentiometer and/or sensor to indicate the movement ofthe users's torso and/or feet and/or head, etc. These one or moresensors may be used to control the platform/mobile platform/roboticassembly in one or more ways. For example, where the user's torsomovement may be sensed, torso forward movement by the user may send asignal to the control system that the mobile platform should moveforward. One or more sensors worn on the user's feet, which may include,but is not limited to, those described in WO 2010/120403 A2, may sendcontrol signals to the robotic assembly and/or the mobile platform.

Control System

WO 2010/120403 A2 includes description of various control systems andmethods for a robotic arm or another robotic assembly. At least part ofthe description may be applicable to the exoskeleton control system.Referring to FIG. 87, in the exemplary embodiment, and used forillustration purposes, the system 8700 includes an exoskeleton 8100which controls at least one robotic arm 8102, 8104. The system 8700 maybe powered by a power source located in a housing 8702. However, inother embodiments, the exoskeleton 8100 may be powered by one powersource and the mobile platform by another power source (not shown). Thisembodiment may be used where the mobile platform 8106 and theexoskeleton 8100 are remote one from another. Thus, in variousembodiments, the user 8704 may be located in a location remote from therobotic assemblies 8102, 8104. However, in some embodiments, the user8704 and the robotic assemblies 8102, 8104 may be located in the samearea.

As discussed above, the various joints of the exoskeleton includesensors such that the movement of the user may be captured by thesensors. The sensors, in the exemplary embodiment, send signals to acontrol system. In various other embodiments, a camera may be used tocapture the movement of the user and send the signals to the controlsystem. In some embodiments if these embodiments of the system, the usermay use a hand portion, which, in some embodiments, may include one ormore of the various sensors described herein, such that the camera maydetermine the gross movements of the user and the hand portion may sendsignals regarding the movement of the hand and/or fine movements.However, for description purposes, the exoskeleton embodiment isdescribed below, although it should be understood that the system mayinclude one or more devices, apparatus and/or systems to capture theuser movements (both gross and fine) and send signals to the controlsystem indicating the movements such that the control system may map themovement to the one or more robotic assemblies. Thus, in the variousembodiments, the control system maps the movement of the exoskeleton tothe movement of the robotic assemblies. For purposes of illustration,the exemplary embodiment will be used to describe the controls.

In the exemplary embodiment, the control system is a many to one or manyto few mapping system. The movement of the user is captured by the oneor more sensors of the exoskeleton. The movement data is sent to thecontrol system which maps the movement and sends commands for movementto the at least one robotic assembly. Various embodiments may includepreprogrammed gestures and/or preprogrammed signals that may be made bythe user and automatically translated to a particular movement and/ormovements of the robotic assembly. In this way, the user may easily,efficiently and with little to no training, control the at least onerobotic assembly.

Further, as the exoskeleton allows the user to move in a natural way,and translate these natural movements to movements by the at least onerobotic assembly, control of the at least one robotic assembly is easyand efficient and, as well, does not require extensive training. Withrespect to the exemplary embodiment, where the exoskeleton controls tworobotic arms, the robotic arms move in a natural/human manner. Thus,where the user moves in a natural/human manner, and this movement istranslated to robotic arms which move in natural/human manner, thesystem allows for easy and efficient use of the robotic arms and easyand efficient control, but the user, of the robotic arms, to performnatural/human-like tasks.

In the exemplary embodiment, the control system is calibrated to a user.This calibration, once completed, in some embodiments, may be “saved” or“stored” and recalled by the control system such that multiple users mayuse a single exoskeleton at different times. To do so, they maycalibrate at each use, or, in some embodiments, may upload/load apreviously configured calibration at time of use.

In various embodiments, calibration may be performed either manually orautomatically. For example, in some embodiments, there may be a softwaresystem which takes the user through the calibration process by promptingthe user, wearing the exoskeleton, to position their arms/torso inspecific orientations, one after the next. The system thus may recordthe at least one sensor position/signal at a particular position of thearm. Thus, completing a series of calibration steps, the control systemmay then map movement of the exoskeleton/user to movement by the roboticarm/at least one robotic assembly.

With respect to the exemplary embodiment, where two robotic arms may becontrolled by the exoskeleton, calibration may be particularly importantwith respect to positions where the hands/arms of the robotic arms aretouching/meet/make contact in free space. Thus, it is critical to mapthe joints of the exoskeleton at these points to ensure that the roboticarms will touch when commanded by the user. Thus, in the exemplaryembodiment, it may be critical that the robotic arms are capable ofinteracting with items of interest.

In the exemplary embodiment, after calibration, when the user moveswhile in the exoskeleton, the robotic arms will move in the same manner,i.e., will map to the user/exoskeleton.

Thus, in the exemplary embodiment, the exoskeleton collects data/signalsfrom sensors on two arms of the user. The controls then maps thesepositions, thus, the controls map the joint positions of each of the twoarms of the user directly to the arm positions of each of the respectiverobotic arms 8102, 8104. Thus, the movement of the right arm 8704 of theuser is mapped to move/control the right robotic arm 8102 and so on andso forth with respect to the left arm of the user 8706 and the leftrobotic arm 8104.

With respect to the hands of the user and the robotic arms 8102, 8104,as discussed herein and in WO 2010/120403 A2, the robotic arms includehands which include a plurality of grips. Although as discussed in WO2010/120403 A2, mode switching may be used to control the hands, in theembodiment described herein with respect to the exoskeleton system, modeswitching may not be used. Thus, when the user, wearing the exoskeleton,moves their hands, this movement may be mapped to the robotic arms.

However, in some embodiments, for ease or use and also, to ensure theuser's intended grip is mapped to the robotic arms, gestures may bepreprogrammed to the system as part of a calibration movement. Thus,where, for example, the user is intending to command a pinch grip, butin their hand movement, fails to correctly place their index finger withrespect to their thumb, the robotic arms, without a gesture program, maymimic exactly the movement of the user. Thus, in this case, the roboticarm(s) would move in a user unintended, although commanded, manner.However, in some embodiments where gesture programming is used, whilethe user may not have completed the pinch grip movement correctly, thesystem may interpret the movement as a gesture, and signal to therobotic arm(s) to move to pinch grip. Although “pinch grip” isdiscussed, this is merely an illustrative example, all of the variousgrips and intermediate grips may be commanded by the user via a gesturethat is preprogrammed into the control system.

Additionally, with respect to some embodiments of the hand mapping,where the human hand/fingers may be able to move in various ways, insome embodiments, the robotic arm/hand may not be able to move in all ofthe same ways. Thus, in some embodiments, the control system may bepreprogrammed to interpret the movements by the human hand to specificmovements by the robotic arm/hand, i.e., those movements that therobotic arm/hand are capable of performing. Thus, in some embodiments,the hand mapping may be a many to one or many to few mapping.

For example, in some embodiments, with respect the hand mapping, andspecifically with respect to the index finger, although a user may closetheir index finger in a number of different ways, the control system maymap the user closing their index finger (whichever way the user closesit) to a single way of closing the robotic hand/arm index finger. Thus,in some embodiments, the mapping may be a many to one mapping.Similarly, with respect to the middle, ring and pinky finger, asdiscussed above, the middle finger includes a sensor and, in someembodiments, the ring and pinky do not. Thus, when the user closes theirmiddle finger, in some embodiments, this may translate to a specificclosing of the ring and pinky fingers as well.

Another example is the thumb movements. In some embodiments, althoughthe human thumb may close in a number of different ways, the controlsystem may map these ways to a preprogrammed 2 degrees of freedom.

In some embodiments of the control system, the system is position basedrather than orientation based. Thus, the position of the hand, forexample, rather than the orientation of the hand, commands the roboticarm/hand. This may be desirable for wherever, with respect toorientation, the user's hand is; the user may command movement by thehand without respect to the orientation of the user's hand, rather, onlywith respect to the position of the user's hand. However, in otherembodiments, the system may be orientation and position based.

In various embodiments, the control system need not include endpointcontrol, as discussed in WO 2010/120403 A2. Thus, the user may bemechanically constrained by the exoskeleton and their body to limit themovements commanded to the robotic arms. However, in some embodiments,endpoint control, similar to the embodiments described in WO 2010/120403A2, may be used in the control system for the exoskeleton system.

In some embodiments, a method for freezing the robotic arm and/or handin a particular position may be desired. For example, circumstanceswhere an object may be grasped by one robotic hand while being workedupon by the second robotic hand, it may be desirable that the firstrobotic arm/hand remain in the same position. In some embodiments, inaddition, a user may wish to maintain the robotic arm/hand in a frozenposition for an extended amount of time and “rest” or “free” their armsimultaneously. Therefore, and referring now to FIG. 93, in someembodiments, a method for freezing a robotic arm/hand in a position inshown. The user first moves the first robotic arm/hand to the desiredposition 9300. The user commands the control system to freeze thatparticular robotic arm 9302, which, in some embodiments, may becommanded using voice commands, IMU commands and/or other inputs to thecontrol system. The user then may move their arm/hand without thecontrol system mapping the user movement to the frozen robotic arm/hand9304. When mapping becomes desired 9306, for example, once the secondrobotic arm has finished working on an object controlled by the firstrobotic arm, the user moves their arm/hand to the frozen position 9308and commands the mapping resume 9310. Thus, in some embodiments, themapping will resume seamlessly from the frozen position.

In some embodiments, the robotic arm, in some embodiments, and/or otherrobotic assemblies in various embodiments, may have capabilities beyondthat of the user. For example, the robotic arm may be capable of alonger “wing span” and may be capable of 360 degree rotation. However,the user, for which the control system maps their movement onto therobotic arm, for example, may be unable to command the robotic arm toits full expansion and capability. Thus, in some embodiments, a methodfor extended control may be used. In this method, variouslocations/points in the user movement path may be preprogrammed totrigger a mapping ratio of movement between the user and the movement tothe robotic assembly. For example, at a preprogrammed location, theratio may switch from “one-to-one” to “one-to-two”, and further, at asecond location, the ratio may switch from “one-to-two” to“one-to-three”, etc. In this way, by increasing the mapping ratio, theuser may command the robotic assembly to move in such a way as they cannot. During user calibration, which is discussed in more detail above,the potential paths of the user may be preprogrammed into the systemsand the trigger or switch locations as well as the mapping ratioassociated with the “path” between two locations will be preprogrammed.

As discussed herein, in various embodiments, the robotic hand assemblymay include preprogrammed grip trajectories. These embodiments mayincrease the accuracy of the remotely controlled robotic hand forwithout a preprogrammed trajectory, and where visibility of the fingersof the hand may be obscured on a video feed, the desired grip may bedifficult to achieve. Thus, with preprogrammed trajectories, the usermay instruct (for example, using an IMU) the robotic hand to move to aparticular trajectory and therefore, the trajectory will be achievedregardless of the quality of visualization at the time.

In some embodiments, although each arm of the exoskeleton may weightabout 3 pounds, it may be desirable for an assistance mechanism toalleviate the weight of the arms for the user may become tired overtime. Thus, in some embodiments, the exoskeleton system may includesupporting apparatus/mechanism/means, which, in some embodiments, may bewires that attach to both the arm and a ceiling or other structure, toaid in supporting the arms. In various embodiments, the supportingmechanism may allow for freedom of movement by the user, and, in someembodiments, the supporting mechanism may maintain the arms of theexoskeleton in a fixed position. In some embodiments, the exoskeletonmay include motors and drives inside the joints of the exoskeleton toprovide for less weight experienced by the user.

In various embodiments of the system, the user may wear one or more IMUor other type of sensor, to send additional control signals to thesystem. These additional control signals may be used to control one ormore mobile platforms 8106, one or more sensors, including, but notlimited to, one or more cameras. Referring to FIG. 87, in someembodiments, the exoskeleton 8100 and the mobile platform 8106 androbotic arms 8102, 8104 are hard wired, however, as discussed above, invarious embodiments, they may communicate by way of wirelesscommunications. These wireless communications may be any wirelesscommunications. In some embodiments, the one of more IMU may be used tocontrol the hand grips, as is described in WO 2010/120403 A2.

In some embodiments where the user controls the mobile platform usingone or more IMUs, the user may wear, for example, one IMU on their footto control the forward, backward, right and left movement of the mobileplatform. However, in some embodiments, the user may wear an IMU on boththeir right foot and left foot.

In these embodiments, one of the IMUs (either right or left) may be usedto control the forward, backward, right and left movement of the mobileplatform. The other IMU may be used to select grips on the hand.

Although in some embodiments, the power supply 8702 may be provided in ahousing and hard wired to one or more components of the system, in otherembodiments, one or more power supplies may be worn by the user and/orintegrated with the exoskeleton and/or integrated in the robotic arms8102, 8104 and/or integrated in the mobile platform 8106.

Referring now to FIG. 88, in some embodiments, the user 8704 may belocated remotely from the mobile platform 8106 and thus, remotely fromthe robotic arms and/or one or more robotic assemblies 8102, 8104(hereinafter “robotic arms”). In these embodiments, the exoskeleton 8100commands the mobile platform 8106 and/or robotic arms 8102, 8104 by wayof wireless communications 8802, 8808. Additionally, in someembodiments, the system may include one or more sensors, which, mayinclude, but are not limited to, one or more cameras 8804, 8806,Ultraviolet (“UV”) sensors, thermal sensors and/or Infrared (“IR”)sensors. In various embodiments, additional sensors of any kind may beused and in some embodiments, may be selected based on factors,including, but not limited to, the task in which the robotic assembliesare being used to accomplish. The one or more sensors may be desirableto assist the user 8704 in decision making regarding the task beingperformed.

The cameras 8804, 8806 (which may be any type of camera including, butnot limited to, night vision cameras and underwater cameras) may belocated anywhere desired, including but not limited to, distributedabout the mobile platform 8106 such that they may collect images of thesurroundings of the mobile platform 8106. In some embodiments, there maybe a plurality of cameras such that a 360 degree view may becommunicated to the user 8704. Referring to FIGS. 88-90, in someembodiments, a camera 8804 may be used which may be capable of pivotingand collecting images where the user 8704 desires. In some embodiments,the camera 8804 may be controlled by an IMU or other sensor worn by theuser and/or part of the exoskeleton. In some embodiments, the IMU may beone described in WO 2010/120403 A2. In some embodiments, the camera 8804may be controlled by way of IMU sensors which may be worn on the user'sfeet. In some embodiments, as shown in FIG. 90, the camera 8804 may bemounted anywhere on the mobile platform 8106.

In some embodiments, the one or more cameras 8804, 8806 may transmitimages to the user 8704. The user 8704 may, in some embodiments, viewthe images using LED glasses 8810 and/or at least one monitor/viewingapparatus 9000. In some embodiments, multiple monitors/viewing apparatus9000 are used. Although in FIG. 90, the various system components areshown wired together, it should be understood that in the variousembodiments, one or more components may wirelessly communicate with oneor more components.

In some embodiments, the mobile platform 8106 may include one or moreIMUs and transmit yaw, pitch and roll data to the user by way of one ormore tactors. In some embodiments, the user 8704 may stand on a platformwhich may mimic movement of the mobile platform 8106 thus providedfeedback to the user 8704 regarding terrain, etc. This may be desirableto communicate perspective to the user 8704 for the user 8704 todetermine control strategy.

In some embodiments, as discussed above, the user 8704 may wear one ormore sensors to control the mobile platform 8106. These sensors mayinclude, but are not limited to, one or more of the following:accelerometers, joysticks, IMUs. Thus, in these embodiments, the user8704 may control the mobile platform 8106 using body English to move theplatform.

In practice, the system may be used in any environment and the systemmay be distributed in any way, i.e., the user may be in any location andthe mobile platform/robotic assembly may be in any location. Thus, thesystem may be used to accomplish any type of task including but notlimited to, tasks related to the mining industry. For example, in someembodiments, the user may control two robotic arms to move about a mine,place explosives in the wall of the mine and attach detonation devices.In some embodiments, this task may be accomplished by a user in a remotelocation, far from any danger or harm related to the mine and/or theexplosives. Using one or more sensors, which, in some embodiments, maybe one or more cameras, are used such that the user may follow theprogress of the robotic arms and the explosives. Also, in someembodiments, because the robotic arm moves naturally, the user mayperform the task using “dummy” explosives and walls, while the mobileplatform and robotic arms mimic the user and complete the actual task athand. Many other uses are contemplated for the system described herein,including, but not limited to, Explosive Ordinance Disposal (sometimescommonly referred to as “EOD”).

Referring now to FIG. 91, in some embodiments, a base station 9100 maybe used for wireless communication between the user/exoskeleton and therobotic assembly 9112. When navigating, communication with the roboticassembly 9112 may become interrupted due to the environment, forexample, due to reflection on hard surfaces. Thus, in some embodiments,small, low power radio communication modules 9102, 9104 that act asrelays may be used. Thus, as the robotic assembly 9112 moves about thearea 9110, it will maintain communication with the base station 9100and, in some embodiments, measure the signal strength of thecommunications. In some embodiments, when the signal strength reducesto, or below, a minimum threshold strength (which, threshold may bepredetermined based on the signal strength needed to continuecommunication between the base station 9100 and robotic assembly 9112,the robot may place a small, low power base relay radio 9102, 9104 ontothe area 9110. As shown in FIG. 91, for illustration purposes, therobotic assembly 9112, including a mobile platform 9106 and a roboticarm 9108, determined that the radio strength is at or below thepredetermined minimum threshold strength, a placed a first low powerbase relay radio 9102, then a second low power base relay radio 9104onto the area 9110. In some embodiments, the low power base relay radios9102, 9104 may be approximately 1 inch in diameter. FIG. 91 and thedescription thereto is an example of one embodiment. In variousembodiments, multiple low power base relay radios may be used.

Referring now to FIG. 92A-92C, in some embodiments, where a mobileplatform is used, maneuvering in small, confined areas with or withoutuneven topography including, but not limited to, inclines, declines,deep trenches and steep vertical faces, may be improved using a systemincluding a mobile platform configuration that may be stacked (see FIG.92A) to allow subsequent mobile platforms 9200 to use the stack ofmobile platforms 9202, 9204, 9206 as a ladder or step configuration. Insome embodiments, the mobile platforms 9202, 9204, 9206 in the stackedconfiguration may either move a robotic assembly attached thereto priorto stacking, or, in some embodiments, the mobile platforms 9202, 9204,9206 may be used to assist the mobile platform 9200 that includes therobotic arm 9208. In some embodiments, the robotic arm 9208 on themobile platform 9200 may be extended so as to position the center ofgravity onto the front wheel of the mobile platform 9200.

Referring now to FIG. 92B, in some embodiments, the stacked mobileplatforms may be replaced by moveable stacking blocks 9212, 9214, 9216.In some embodiments, and as shown in FIG. 92B, the robotic arm 9208,including a hand assembly 9210, may use a hand grip for climbing assistfor example, for heavier payloads. In some embodiments, the stackingblocks 9212, 9214, 9216 may include hand holds for the hand assembly9210 to grip for assistance.

Referring now to FIG. 92C, in some embodiments, for example, to overcomeobstacles of some sizes, a second robotic arm 9218 on a second mobileplatform 9224 may lift a first mobile platform 9222 by holding onto thefirst robotic arm 9220 on the first mobile platform 9222. When the firstmobile platform 9222 is resting on a surface, the first robotic arm 9220of the first mobile platform 9222 may then lift the second mobileplatform 9224 by pulling up on the second robotic arm 9218.

In the exemplary embodiment where two robotic arms such as thosedescribed here are used, any task that requires a tool and/or machineryand/or device that is used by humans may be used by the robotic arms. Insome embodiments, the hand of the robotic arm may be removable by theother robotic arm, and replaced with an end effecter.

Although the invention has been described in the context of a prostheticarm, an apparatus according to the elements of this invention could beused in other robotic tools, such as those used in manufacturing and/orteleoperations, where an operator is not connected directly to thecontrolled device. For example the prosthetic arm apparatus may be usedfor teleoperation in hazardous environments and/or hazardous activities,for the detonation of explosive devices or the like. In theseenvironments, the prosthetic arm apparatus may provide a more intuitiveinterface for the user since the user will already be familiar with thenatural movements of the arm, which may make control translation of theprosthetic arm apparatus easier.

While the principles of the invention have been described herein, it isto be understood by those skilled in the art that this description ismade only by way of example and not as a limitation as to the scope ofthe invention. Other embodiments are contemplated within the scope ofthe present invention in addition to the exemplary embodiments shown anddescribed herein. Modifications and substitutions by one of ordinaryskill in the art are considered to be within the scope of the presentinvention.

What is claimed is:
 1. A robotic assembly control system comprising: anexoskeleton apparatus adapted to be worn by a user comprising at leastone tactor motor; at least one robotic assembly, separate from theexoskeleton, the at least one robotic assembly controlled by the user byway of the exoskeleton, the at least one robotic assembly comprising arobotic arm comprising: a hand assembly; and a shoulder joint; and atleast one mobile platform comprising at least one wheel, the at leastone mobile platform controlled by the user and separate from theexoskeleton and wherein the at least one robotic assembly is attached tothe at least one mobile platform, wherein the at least one tactor motorprovides feedback related to torque of the shoulder joint on the atleast one robotic assembly.
 2. The robotic assembly control system ofclaim 1, the exoskeleton further comprising: an attachment systemcomprising a plurality of straps, the attachment system for attaching toa user; and a frame comprising a lower portion and an upper portionwherein the upper portion telescopingly connects to the lower portionwherein the frame is adjustable.
 3. The robotic assembly control systemof claim 2, the frame further comprising a ball detent mechanism foradjusting the frame.
 4. The robotic assembly control system of claim 1,further comprising at least one potentiometer.
 5. The robotic assemblycontrol system of claim 1, further comprising at least two ball joints.6. The robotic assembly control system of claim 1, further comprising acompliance section wherein the compliance section sensessternoclavicular motion by a user.
 7. The robotic assembly controlsystem of claim 6, wherein the compliance section is a torsion spring.8. The robotic assembly control system of claim 7, wherein the torsionspring is preloaded with a hard stop, wherein the hard stop isadjustable.
 9. The robotic assembly control system of claim 1, furthercomprising a tactor strap for each tactor motor wherein the tactor strapattaches to a user.
 10. The robotic assembly control system of claim 9,wherein the at least one tactor motor is a vibration motor.
 11. Therobotic assembly of claim 1, wherein the hand portion comprising: athumb force sensor; an index finger sensor; and a middle finger sensor.12. The robotic assembly control system of claim 11, the hand portioncomprising at least one tactor motor wherein the tactor motor providesfeedback of the robotic assembly thumb force sensor to the user.
 13. Therobotic assembly control system of claim 11, the thumb force sensorfurther comprising at least one potentiometer.
 14. The robotic assemblyof claim 1, wherein the hand assembly comprising: a thumb structure; anindex finger structure; and a middle finger structure.
 15. A method forcontrolling a robotic assembly comprising: providing an exoskeletonapparatus adapted to be worn by a user comprising at least one tactormotor; providing at least one robotic assembly, separate from theexoskeleton, the at least one robotic assembly controlled by the user byway of the exoskeleton, the at least one robotic assembly comprising arobotic arm comprising: a hand assembly; and a shoulder joint; andproviding at least one mobile platform comprising at least one wheel,the at least one mobile platform controlled by the user and separatefrom the exoskeleton and wherein the at least one robotic assembly isattached to the at least one mobile platform, wherein the at least onetactor motor providing feedback related to torque of the shoulder jointon the at least one robotic assembly, and wherein the at least onerobotic assembly moving in response to movement of the exoskeleton. 16.The method of claim 15, further comprising providing at least onepotentiometer.
 17. The method of claim 15, further comprising providinga compliance section and sensing the sternoclavicular motion by a user.18. The method of claim 15, wherein the at least one tactor motor is avibration motor.
 19. The method of claim 15, wherein the hand portioncomprising: a thumb force sensor; an index finger sensor; and a middlefinger sensor.
 20. The method of claim 19, further comprising providingat least one tactor motor in the hand portion, the tactor motorproviding feedback of the robotic assembly thumb force sensor to theuser.